Cross-linked polycarbonate resin with improved chemical and flame resistance

ABSTRACT

Disclosed herein are compositions including a cross-linked polycarbonate. The cross-linked polycarbonate may be derived from a polycarbonate having about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone. A plaque including the composition can achieve a UL94 5VA rating. Also disclosed herein are articles including the compositions, methods of using the compositions, and processes for preparing the compositions.

This application is a divisional of U.S. patent application Ser. No.14/137,002, filed Dec. 20, 2013, which claims priority to U.S.Provisional Patent Application Ser. No. 61/740,062, filed Dec. 20, 2012.The disclosure of those applications is hereby fully incorporated byreference herein.

TECHNICAL FIELD

The present disclosure relates generally to cross-linked polycarbonates,compositions comprising the cross-linked polycarbonates, and articlescomprising the cross-linked polycarbonates.

BACKGROUND

Polycarbonates are polymers that may be derived from bisphenols andphosgene, or their derivatives. They are useful for forming a widevariety of products, such as by molding, extrusion, and thermoformingprocesses. Such products include articles and components that includeauto parts, electronic appliances and cell phone components. Because oftheir broad use, particularly in electronic applications and auto partapplications, the desired properties of polycarbonates include highimpact strength and toughness, heat resistance, weather and ozoneresistance, and good ductility.

Bisphenol-A based polycarbonate is inherently flame retardant, howeverthe material drips when exposed to flame, and this behavior worsens asthe thickness of the material decreases (e.g., 3 mm or less). Thisdiminishes greatly its use in clear thin wall applications where UL 94V0 ratings, as well as 5VA ratings are required.

Accordingly, there exists a need for improved polycarbonate compositionsthat exhibit UL 94 V0 and 5VA performance characteristics, whilemaintaining physical and mechanical properties suitable for the intendedapplication. There also exists a need for polycarbonate compositionsthat can be used to provide transparent, thin-walled articles havingUL94 V0 and 5VA performance characteristics.

SUMMARY

Disclosed herein are compositions comprising cross-linkedpolycarbonates, articles comprising the compositions, and processes forpreparing the compositions and articles.

In one aspect, disclosed is a composition comprising a cross-linkedpolycarbonate, the cross-linked polycarbonate derived from anon-cross-linked polycarbonate comprising about 0.5 mol % to about 5 mol% endcap groups derived from a monohydroxybenzophenone; and a flameretardant; wherein a plaque comprising the composition achieves a UL945VA rating at a thickness of 3.0 mm (±10%) or less.

In certain embodiments, the non-cross-linked polycarbonate comprisesabout 1 mol % to about 3 mol % endcap groups derived from amonohydroxybenzophenone, or about 2 mol % to about 2.5 mol % endcapgroups derived from a monohydroxybenzophenone.

In certain embodiments, the plaque comprising the composition achieves aUL94 5VA rating at a thickness equal to or less than 2.5 mm (±10%),equal to or less than 2.0 mm (±10%), or equal to or less than 1.5 mm(±10%).

In certain embodiments, the flame retardant is potassium perfluorobutanesulfonate (Rimar salt), potassium diphenyl sulfone-3-sulfonate (KSS), ora combination thereof.

In one preferred embodiment, the flame retardant is potassiumperfluorobutane sulfonate (Rimar salt). The composition may furthercomprise a cyclic siloxane, which may be octaphenylcyclotetrasiloxane.

In certain embodiments, the flame retardant is present in an amount ofabout 0.08 wt or less, based on the total weight of the composition.

In certain embodiments, the flame retardant is potassium diphenylsulfone-3-sulfonate (KSS).

In certain embodiments, the composition achieves a UL94 5VA rating inthe absence of a brominated and/or chlorinated flame retardant.

In certain embodiments, the plaque comprising the composition has atransparency of 70% or greater at a thickness of 3.2 mm, measuredaccording to ASTM-D1003-00, or a transparency of 70%-90% at a thicknessof 3.2 mm, measured according to ASTM-D1003-00. In certain embodiments,the plaque comprising the composition has a haze value of less than 10%at a thickness of 3.2 mm, measured according to ASTM D1003-00.

In certain embodiments, an ASTM part comprising the composition has fullductility under multiaxial impact test conditions per ASTM D3763 at −30°C. determined using a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thickdisk sample, ½-inch (12.7 mm) diameter dart, and an impact velocity of3.3 meters per second (m/s). In certain embodiments, an ASTM Type 1tensile bar part comprising the composition has an elongation at breakof at least 100% using the ASTM D 638 Type I method at 50 mm/min afterexposure to acetone under 1% strain at 23° C. In certain embodiments, anASTM part comprising the composition has an elongation at break of 50%to about 200% according to ASTM D 638.

In certain embodiments, the non-cross-linked polycarbonate has amolecular weight greater than 17,000 Daltons, as measured by gelpermeation chromatography using polycarbonate standards, a molecularweight greater than 17,000 Daltons and less than or equal to 80,000Daltons, as measured by gel permeation chromatography usingpolycarbonate standards, or a molecular weight greater than 17,000Daltons and less than or equal to 35,000 Daltons, as measured by gelpermeation chromatography using polycarbonate standards.

In certain embodiments, the non-cross-linked polycarbonate has a meltvolume flow rate ranging from about 5 to about 30 cc/10 min at 300°C./1.2 kg.

In certain embodiments, the monohydroxybenzophenone is4-hydroxybenzophenone.

In certain embodiments, the cross-linked polycarbonate comprisesrepeating units derived from bisphenol-A.

In certain embodiments, the non-cross-linked polycarbonate has repeatingunits having branching groups.

In certain embodiments, the non-cross-linked polycarbonate resincomprises a compound of formula (I),

wherein each repeating unit —O—Z—OC(═O)— is independently derived from acarbonate source and

-   -   (i) a monomer having the structure HO-A₁-Y₁-A₂-OH wherein each        of    -   A₁ and A₂ comprise a monocyclic divalent arylene group, and Y₁        is a bridging group having one or more atoms; or    -   (ii) a monomer having the structure

-   -   wherein each R^(h) is independently a halogen atom, a C₁-C₁₀        hydrocarbyl, or a halogen substituted C₁-C₁₀ hydrocarbyl, and n        is 0 to 4;

R¹ is halogen, C₁-C₆ alkyl, C₃-C₈ cycloalkyl, aryl, or arylalkyl;

R² is halogen, C₁-C₆ alkyl, C₃-C₈ cycloalkyl, aryl, or arylalkyl;

x is 0, 1, 2, 3, or 4;

y is 0, 1, 2, 3, 4, or 5; and

n′ ranges from 29 to 65.

In certain embodiments, the non-cross-linked polycarbonate resincomprises a compound of formula (II):

wherein n′ ranges from 29 to 65.

In certain embodiments, the composition contains at least 5 wt % of aninsoluble methylene chloride insoluble fraction in a 1 mm thick film.

In certain embodiments, the composition is a blend comprising thecross-linked and/or cross-linkable polycarbonate, and one or moreadditional components. The composition may comprise one or moreadditional polymers, and optionally one or more additives. Thecomposition may comprise a p-cumyl phenol cappedpoly(isophthalate-terephthalate-resorcinol ester)-co-(bisphenol-Acarbonate) polymer. The composition may comprise a polycarbonatepolysiloxane copolymer wherein the polysiloxane content is from 0.4 wt %to 25 wt %. The composition may comprise a polycarbonate polysiloxanecopolymer wherein the polysiloxane content is from about 6 wt % siloxane(±10%) to about 25 wt % siloxane (±10%). The polycarbonate polysiloxanecopolymer may be a siloxane block co-polycarbonate comprising 20 wt %siloxane (±10%). The polycarbonate polysiloxane copolymer may be asiloxane block co-polycarbonate comprising 6 wt % siloxane (±10%). Incertain embodiments, the potassium perfluorobutane sulfonate (Rimarsalt) is present in an amount of about 0.06 wt % to about 0.08 wt %.

In certain embodiments, the cross-linked polycarbonate does not containany soft block segments, such as from aliphatic polyesters, aliphaticpolyethers, aliphatic polythioeithers, aliphatic polyacetals, aliphaticpolycarbonates, C—C linked polymers, or polysiloxanes. In certainembodiments, the cross-linked polycarbonate does not contain anyrepeating units derived from a dihydroxybenzophenone, atrihydroxybenzophenone, or a tetrahydroxybenzophenone.

In another aspect disclosed is a composition comprising a cross-linkedpolycarbonate derived from a non-cross-linked polycarbonate comprisingabout 0.5 mol % to about 5 mol % endcap groups derived from amonohydroxybenzophenone; wherein a plaque comprising the compositionfurther, comprising potassium perfluorobutane sulfonate (Rimar salt) inan amount of about 0.05 wt % to about 0.085 wt %, based on the totalweight of the composition, achieves a UL94 5VA rating at a thickness of3.0 mm (±10%) or less. In certain embodiments, the composition achievesa UL94 5VA rating in the absence of a brominated and/or chlorinatedflame retardant. In certain embodiments, the plaque comprising thecomposition has a transparency of 70% to 90% at a thickness of 3.2 mm,measured according to ASTM-D1003-00.

In another aspect, disclosed are articles comprising the compositionsdisclosed herein.

In certain embodiments, the article is at least one of an automotivebumper, an automotive exterior component, an automobile mirror housing,an automobile wheel cover, an automobile instrument panel or trim, anautomobile glove box, an automobile door hardware or other interiortrim, an automobile exterior light, an automobile part within the enginecompartment, an agricultural tractor or device part, a constructionequipment vehicle or device part, a marine or personal water craft part,an all terrain vehicle or all terrain vehicle part, plumbing equipment,a valve or pump, an air conditioning heating or cooling part, a furnaceor heat pump part, a computer part, a computer router, a desk topprinter, a large office/industrial printer, an electronics part, aprojector part, an electronic display part, a copier part, a scannerpart, an electronic printer toner cartridge, a hair drier, an iron, acoffee maker, a toaster, a washing machine or washing machine part, amicrowave, an oven, a power tool, an electric component, an electricenclosure, a lighting part, a dental instrument, a medical instrument, amedical or dental lighting part, an aircraft part, a train or rail part,a seating component, a sidewall, a ceiling part, cookware, a medicalinstrument tray, an animal cage, fibers, a laser welded medical device,fiber optics, a lense (auto and non-auto), a cell phone part, agreenhouse component, a sun room component, a fire helmet, a safetyshield, safety glasses, a gas pump part, a humidifier housing, athermostat control housing, an air conditioner drain pan, an outdoorcabinet, a telecom enclosure or infrastructure, a Simple NetworkDetection System (SNIDS) device, a network interface device, a smokedetector, a component or device in a plenum space, a medical scanner,X-ray equipment, a construction or agricultural equipment, and a turbineblade.

In certain embodiments, the composition is comprised in a firstthickness of the article as measured from an external surface of saidarticle, the first thickness being 20 micron or less.

In certain embodiments, the article, or a material in the article,requires a UL94 5VA rating performance. The article may be at least oneof a computer housing, a computer housing or business machine housing orpart, a housing or part for monitors, a computer router, a copier, adesk top printer, a large office/industrial printer, a handheldelectronic device housing such as a computer or business machinehousing, a housing for a hand-held device, a component for a lightfixture including LED fixtures or home or office appliances, ahumidifier housing, a thermostat control housing, an air conditionerdrain pan, an outdoor cabinet, a telecom enclosure or infrastructure, aSimple Network Intrusion Detection System (SNIDS) device, a networkinterface device, a smoke detector, a component or device in a plenumspace, a component for a medical application or a device such as amedical scanner, X-ray equipment, or ultrasound device, an electricalbox or enclosure, and an electrical connector.

In another aspect, disclosed is a process for preparing an articlecomprising the composition disclosed herein. The process may comprise(a) providing a first composition comprising a non-cross-linkedpolycarbonate comprising about 0.5 mol % to about 5 mol % endcap groupsderived from a monohydroxybenzophenone; and a flame retardant; (b)molding the composition of step (a) into an article, and/or coating anarticle with the composition of step (a); and (c) exposing the moldedarticle and/or coated article of step (b) to UV-radiation to affectcross-linking of the non-cross-linked polycarbonate.

In certain embodiments, step (c) comprises passing the article of step(b) through a UV-chamber, a UV-containing light source, or exposing thearticle to the sun.

In certain embodiments, the article is treated with UV radiation for 90seconds, providing an energy of irradiation of 3,000 mJ/cm².

In certain embodiments, the cross-linking occurs at the surface of themolded article or surface of the coating to a depth of 20 microns orless, as measured by FTIR by the loss of the benzophenone ketone.

In certain embodiments, step (b) includes extrusion processes,multilayer extrusion processes, and combinations thereof.

In certain embodiments, the molded article and/or coated article of step(b) includes a multilayer sheet or multilayer film, where at least oneof the outer layers comprise a composition disclosed herein.

In certain embodiments, the article prepared by the process is at leastone of an automotive bumper, an automotive exterior component, anautomobile mirror housing, an automobile wheel cover, an automobileinstrument panel or trim, an automobile glove box, an automobile doorhardware or other interior trim, an automobile exterior light, anautomobile part within the engine compartment, an agricultural tractoror device part, a construction equipment vehicle or device part, amarine or personal water craft part, an all terrain vehicle or allterrain vehicle part, plumbing equipment, a valve or pump, an airconditioning heating or cooling part, a furnace or heat pump part, acomputer part, a computer router, a desk top printer, a largeoffice/industrial printer, an electronics part, a projector part, anelectronic display part, a copier part, a scanner part, an electronicprinter toner cartridge, a hair drier, an iron, a coffee maker, atoaster, a washing machine or washing machine part, a microwave, anoven, a power tool, an electric component, an electric enclosure, alighting part, a dental instrument, a medical instrument, a medical ordental lighting part, an aircraft part, a train or rail part, a seatingcomponent, a sidewall, a ceiling part, cookware, a medical instrumenttray, an animal cage, fibers, a laser welded medical device, fiberoptics, a lense (auto and non-auto), a cell phone part, a greenhousecomponent, a sun room component, a fire helmet, a safety shield, safetyglasses, a gas pump part, a humidifier housing, a thermostat controlhousing, an air conditioner drain pan, an outdoor cabinet, a telecomenclosure or infrastructure, a Simple Network Detection System (SNIDS)device, a network interface device, a smoke detector, a component ordevice in a plenum space, a medical scanner, X-ray equipment, aconstruction or agricultural equipment, and a turbine blade.

In certain embodiments, the article, or a material in the article,requires a UL94 5VA rating performance. The article may be at least oneof a computer housing, a computer housing or business machine housing orpart, a housing or part for monitors, a computer router, a copier, adesk top printer, a large office/industrial printer, a handheldelectronic device housing such as a computer or business machinehousing, a housing for a hand-held device, a component for a lightfixture including LED fixtures or home or office appliances, ahumidifier housing, a thermostat control housing, an air conditionerdrain pan, an outdoor cabinet, a telecom enclosure or infrastructure, aSimple Network Intrusion Detection System (SNIDS) device, a networkinterface device, a smoke detector, a component or device in a plenumspace, a component for a medical application or a device such as amedical scanner, X-ray equipment, or ultrasound device, an electricalbox or enclosure, and an electrical connector.

The compositions, articles, methods, and processes are further describedherein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts polycarbonate composition molecular weight as a functionof UV-exposure.

FIG. 2 depicts the molecular weight build (%) as a function of4-hydroxybenzophenone endcap content in polycarbonate compositionstreated with UV-radiation.

FIG. 3 depicts overlayed NMR spectra demonstrating peak intensityincrease at 3.48 ppm showing progression of polycarbonate cross-linking

FIG. 4 depicts NMR peak intensity at 3.48 ppm as a function ofUV-treatment of 4-hydroxybenzophenone endcapped polycarbonates.

FIG. 5 depicts polycarbonate composition molecular weight as a functionof sun exposure time.

FIG. 6 depicts small amplitude oscillatory rheology [parallel-plate] ofa low-flow BPA-polycarbonate resin.

FIG. 7 depicts small amplitude oscillatory rheology [parallel-plate] ofa low-flow benzophenone endcapped BPA-polycarbonate copolymer resin.

FIG. 8 depicts field emission microscopy images of the skin of tensilebars comprising cross-linked polycarbonates.

DETAILED DESCRIPTION

Disclosed herein are compositions comprising a cross-linkedpolycarbonate. The compositions have improved flame retardance overconventional clear polycarbonates, including improved flame resistanceperformance characteristics, such as flame out time (FOT) and time todrip (TTD). The compositions, blended or neat, can be used to providethin-walled materials that are UL94 5VA compliant. The compositions canbe used to provide thin-walled materials that are 5VA compliant andhighly transparent. The compositions may also exhibit good chemicalresistance, scratch resistance, tear resistance, impact strength,ductility, hydrolytic stability, and/or weatherability.

The compositions disclosed herein are derived from cross-linkablepolycarbonates comprising monohydroxybenzophenone derived endcaps. Thesepolycarbonates, prior to cross-linking, can be provided as thermallystable high melt-flow polymers, and can thus be used to fabricate avariety of thin-walled articles (e.g., 3 mm or less). These articles maysubsequently be treated (e.g., with UV-radiation) to affectcross-linking, thereby providing thin-walled materials that meet desiredperformance requirements (e.g., 5VA performance, chemical resistance,transparency). The cross-linked materials, in addition to flameresistance and chemical resistance, may retain or exhibit superiormechanical properties (e.g., impact resistance, ductility) as comparedto the composition prior to cross-linking

The use of monohydroxybenzophenone derived endcaps provides severaladvantages over polycarbonates incorporating repeating units derivedfrom dihydroxybenzophenone monomers. Specifically, themonohydroxybenzophenone endcap is more economical, as less monomer istypically used. In addition, incorporation of themonohydroxybenzophenone into the polycarbonate can be particularlycontrolled, as the monohydroxybenzophenone will only react as a chainstopper. Accordingly, use of monohydroxybenzophenone eliminates the needfor careful monitoring of polymerization kinetics or how the monomer isincorporated, as compared with a corresponding dihydroxybenzophenonemonomer.

The polycarbonates comprising monohydroxybenzophenone derived endcapscan be blended with other polymers and additives, and yet still besufficiently cross-linked to provide compositions that exhibit one ormore of UL 94 5VA compliance, extreme chemical resitance, scratchresistance, tear resistance, impact strength, ductility, hydrolyticstability, and weatherability. For example, polycarbonates comprisingmonohydroxybenzophenone derived endcaps can be blended with weatheringpolymers (e.g., poly(isophthalate-terephthalate-resorcinolester)-co-(bisphenol-A carbonate) copolymer) and subsequentlycross-linked to provide materials and articles possessing desired flameresistance (e.g., V0, 5VA), chemical resistance, scratch resistance,tear resistance, impact strength, ductility, hydrolytic stability,and/or weatherability.

The compositions disclosed herein are useful in the manufacture of awide variety of articles, particularly thin-walled articles, includinghighly transparent thin-walled articles, having improved flameretardance and good physical properties. The compositions can be used toprovide materials and articles such as, but not limited to, injectionmolded articles, films, extruded sheets, fibers, pellets, flex-films,tear-resistant films, and PVD laminates. The compositions can be used toprovide materials and articles having scratch resistance. Thecompositions can be used to provide materials and articles that haveself-sealing properties (e.g., a scratched article may undergocross-linking upon UV-exposure, thereby sealing the scratch).

The compositions, articles, methods, and processes are further describedherein.

1. DEFINITIONS

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art. In case of conflict, the present document, includingdefinitions, will control. Preferred methods and materials are describedbelow, although methods and materials similar or equivalent to thosedescribed herein can be used in practice or testing of the presentinvention. All publications, patent applications, patents and otherreferences mentioned herein are incorporated by reference in theirentirety. The materials, methods, and examples disclosed herein areillustrative only and not intended to be limiting.

The terms “comprise(s),” “include(s),” “having,” “has,” “can,”“contain(s),” and variants thereof, as used herein, are intended to beopen-ended transitional phrases, terms, or words that do not precludethe possibility of additional acts or structures. The singular forms“a,” “and” and “the” include plural references unless the contextclearly dictates otherwise. The present disclosure also contemplatesother embodiments “comprising,” “consisting of” and “consistingessentially of,” the embodiments or elements presented herein, whetherexplicitly set forth or not.

The modifier “about” used in connection with a quantity is inclusive ofthe stated value and has the meaning dictated by the context (forexample, it includes at least the degree of error associated with themeasurement of the particular quantity). The modifier “about” shouldalso be considered as disclosing the range defined by the absolutevalues of the two endpoints. For example, the expression “from about 2to about 4” also discloses the range “from 2 to 4.” The term “about” mayrefer to plus or minus 10% of the indicated number. For example, “about10%” may indicate a range of 9% to 11%, and “about 1” may mean from0.9-1.1. Other meanings of “about” may be apparent from the context,such as rounding off, so, for example “about 1” may also mean from 0.5to 1.4.

“Alkyl” as used herein may mean a linear, branched, or cyclichydrocarbyl group, such as a methyl group, ethyl group, n-propyl group,isopropyl group, n-butyl group, isobutyl group, tert-butyl group,n-pentyl group, isopentyl group, n-hexyl group, isohexyl group,cyclopentyl group, cyclohexyl group, and the like.

“Aryl” as used herein may mean a substituted or unsubstituted arylradical containing from 6 to 36 ring carbon atoms. Examples of arylinclude, but are not limited to, a phenyl group, a bicyclic hydrocarbonfused ring system, or a tricyclic hydrocarbon fused ring system whereinone or more of the rings are a phenyl group.

“Arylalkyl” as used herein may mean an aryl, as defined herein, appendedto the parent molecular moiety through an alkyl, as defined herein.

“Copolymer” as used herein may mean a polymer derived from two or morestructural unit or monomeric species, as opposed to a homopolymer, whichis derived from only one structural unit or monomer.

“C₃-C₆ cycloalkyl” as used herein may mean cyclopropyl, cyclobutyl,cyclopentyl or cyclohexyl.

“Glass Transition Temperature” or “Tg” as used herein may mean themaximum temperature that a polymer, such as a polycarbonate, will haveone or more useful properties. These properties include impactresistance, stiffness, strength, and shape retention. The Tg of apolycarbonate therefore may be an indicator of its useful uppertemperature limit, particularly in plastics applications. The Tg may bemeasured using a differential scanning calorimetry method and expressedin degrees Celsius.

The glass transition temperature of a polymer, such as a polycarbonate,may depend primarily on the composition of the polymer. Polycarbonatesthat are formed from monomers having more rigid and less flexiblechemical structures than Bisphenol-A generally have higher glasstransition temperatures than Bisphenol-A polycarbonate, whilepolycarbonates that are formed from monomers having less rigid and moreflexible chemical structures than Bisphenol-A generally have lower glasstransition temperatures than Bisphenol-A polycarbonate. For example, apolycarbonate formed from 33 mole % of a rigid monomer,3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one (“PPPBP”), and 67 mole% Bisphenol-A has a glass transition temperature of 198° C., while apolycarbonate formed from Bisphenol-A, but also having 6 wt % ofsiloxane units, a flexible monomer, has a glass transition temperatureof 145° C.

Mixing of two or more polycarbonates having different glass transitiontemperatures may result in a glass transition temperature value for themixture that is intermediate between the glass transition temperaturesof the polycarbonates that are mixed.

The glass transition temperature of a polycarbonate may also be anindicator of the molding or extrusion temperatures required to formpolycarbonate parts. The higher the glass transition temperature of thepolycarbonate the higher the molding or extrusion temperatures that areneeded to form polycarbonate parts.

The glass transition temperatures (Tg) described herein are measures ofheat resistance of, for example, polycarbonate and polycarbonate blends.The Tg can be determined by differential scanning calorimetry. Thecalorimetry method may use a TA Instruments Q1000 instrument, forexample, with setting of 20° C./min ramp rate and 40° C. starttemperature and 200° C. end temperature

“Halo” as used herein may be a substituent to which the prefix isattached is substituted with one or more independently selected halogenradicals. For example, “C₁-C₆ haloalkyl” means a C₁-C₆ alkyl substituentwherein one or more hydrogen atoms are replaced with independentlyselected halogen radicals. Non-limiting examples of C₁-C₆ haloalkylinclude chloromethyl, 1-bromoethyl, fluoromethyl, difluoromethyl,trifluoromethyl, and 1,1,1-trifluoroethyl. It should be recognized thatif a substituent is substituted by more than one halogen radical, thosehalogen radicals may be identical or different (unless otherwisestated).

“Halogen” or “halogen atom” as used herein may mean a fluorine,chlorine, bromine or iodine atom.

“Haze” as used herein may mean that percentage of transmitted light,which in passing through a specimen deviates from the incident beam byforward scattering. Percent (%) haze may be measured according to ASTM D1003-07.

“Heteroaryl” as used herein may mean any aromatic heterocyclic ringwhich may comprise an optionally benzocondensed 5 or 6 memberedheterocycle with from 1 to 3 heteroatoms selected among N, O or S. Nonlimiting examples of heteroaryl groups may include pyridyl, pyrazinyl,pyrimidinyl, pyridazinyl, indolyl, imidazolyl, thiazolyl, isothiazolyl,pyrrolyl, phenyl-pyrrolyl, furyl, phenyl-furyl, oxazolyl, isoxazotyl,pyrazolyl, thienyl, benzothienyl, isoindolinyl, benzoimidazolyl,quinolinyl, isoquinolinyl, 1,2,3-triazolyl, 1-phenyl-1,2,3-triazolyl,and the like.

“Hindered phenol stabilizer” as used herein may mean3,5-di-tert-butyl-4-hydroxyhydrocinnamic acid, octadecyl ester.

“Melt Volume Rate” (MVR) as used herein may mean the flow rate of apolymer in a melt phase as determined using the method of ASTM 1238-10.The MVR of a molten polymer is measured by determining the amount ofpolymer that flows through a capillary of a specific temperature over aspecified time using standard weights at a fixed temperature. MVR isexpressed in cubic centimeter per 10 minutes. The higher the MVR valueof a polymer at a specific temperature, the greater the flow of thatpolymer at that specific temperature.

“Peak melt viscosity” as used herein may mean the highest melt viscosityvalue (in poise) achieved between 350° C. and 450° C. during rheologicaltesting of a polycarbonate resin.

“Percent transmission” or “% transmission” as used herein may mean theratio of transmitted light to incident light and may be measuredaccording to ASTM D 1003-07.

“PETS release agent” as used herein may mean pentaerythritoltetrastearate, mold release.

“Phosphite stabilizer” as used herein may meantris-(2,4-di-tert-butylphenyl) phosphite.

“Polycarbonate” as used herein may mean an oligomer or polymercomprising residues of one or more polymer structural units, ormonomers, joined by carbonate linkages.

“Straight or branched C₁-C₃ alkyl” or “straight or branched C₁-C₃alkoxy” as used herein may mean methyl, ethyl, n-propyl, isopropyl,methoxy, ethoxy, n-propoxy and isopropoxy.

Unless otherwise indicated, each of the foregoing groups may beunsubstituted or substituted, provided that the substitution does notsignificantly adversely affect synthesis, stability, or use of thecompound.

The terms “structural unit” and “monomer” are interchangeable as usedherein.

“Thermal stability” as used herein refers to resistance of a polymer tomolecular weight degradation under thermal conditions. Thus, a polymerwith poor thermal stability may show significant molecular weightdegradation under thermal conditions, such as during extrusion, molding,thermoforming, hot-pressing, and like conditions. Molecular weightdegradation may also be manifest through color formation and/or in thedegradation of other properties such as weatherability, gloss,mechanical properties, and/or thermal properties. Molecular weightdegradation can also cause significant variation in processingconditions such as melt viscosity changes.

For the recitation of numeric ranges herein, each intervening numberthere between with the same degree of precision is explicitlycontemplated. For example, for the range of 6-9, the numbers 7 and 8 arecontemplated in addition to 6 and 9, and for the range 6.0-7.0, thenumber 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 areexplicitly contemplated.

2. COMPOSITIONS

Disclosed herein are compositions comprising a cross-linkedpolycarbonate.

The cross-linked polycarbonate may be derived from a non-cross-linkedpolycarbonate comprising about 0.5 mol % to about 5 mol % endcap groupsderived from a monohydroxybenzophenone, about 1 mol % to about 3 mol %endcap groups derived from a monohydroxybenzophenone, about 1.7 mol % toabout 2.5 mol % endcap groups derived from a monohydroxybenzophenone, orabout 2 mol % to about 2.5 mol % endcap groups derived from amonohydroxybenzophenone. The cross-linked polycarbonate may be derivedfrom a non-cross-linked polycarbonate comprising amonohydroxybenzophenone derived endcap content of: 0.5 mol %, 0.6 mol %,0.7 mol %, 0.8 mol %, 0.9 mol %, 1.0 mol %, 1.1 mol %, 1.2 mol %, 1.3mol %, 1.4 mol %, 1.5 mol %, 1.6 mol %, 1.7 mol %, 1.8 mol %, 1.9 mol %,2.0 mol %, 2.1 mol %, 2.2 mol %, 2.3 mol %, 2.4 mol %, 2.5 mol %, 2.6mol %, 2.7 mol %, 2.8 mol %, 2.9 mol %, 3.0 mol %, 3.1 mol %, 3.2 mol %,3.3 mol %, 3.4 mol %, 3.5 mol %, 3.6 mol %, 3.7 mol %, 3.8 mol %, 3.9mol %, 4.0 mol %, 4.1 mol %, 4.2 mol %, 4.3 mol %, 4.4 mol %, 4.5 mol %,4.6 mol %, 4.7 mol %, 4.8 mol %, 4.9 mol %, or 5.0 mol %.

The composition may further comprise a flame retardant, preferably anon-brominated, non-chlorinated flame retardant. The composition maycomprise a flame retardant in an amount of about 0.09 wt % or less,about 0.089 wt % or less, about 0.088 wt % or less, about 0.087 wt % orless, about 0.086 wt % or less, about 0.085 wt % or less, about 0.084 wt% or less, about 0.083 wt % or less, about 0.082 wt % or less, about0.081 wt % or less, about 0.080 wt % or less, about 0.079 wt % or less,about 0.078 wt % or less, about 0.077 wt % or less, about 0.076 wt % orless, about 0.075 wt % or less, about 0.074 wt % or less, about 0.073 wt% or less, about 0.072 wt % or less, about 0.071 wt % or less, about0.070 wt % or less, about 0.069 wt % or less, about 0.068 wt % or less,about 0.067 wt % or less, about 0.066 wt % or less, about 0.065 wt % orless, about 0.064 wt % or less, about 0.063 wt % or less, about 0.062 wt% or less, about 0.061 wt % or less, about 0.060 wt % or less, about0.059 wt % or less, about 0.058 wt % or less, about 0.057 wt % or less,about 0.056 wt % or less, about 0.055 wt % or less, about 0.054 wt % orless, about 0.053 wt % or less, about 0.052 wt % or less, about 0.051 wt% or less, or about 0.050 wt % or less, based on the total weight of thecomposition.

A material comprising the composition may be UL94 V0 compliant. A flamebar comprising the composition may achieve a UL94 V0 rating. A flame barcomprising the composition, optionally in the absence of a brominatedand/or chlorinated flame retardant, may achieve a UL94 V0 rating at athickness of: 3.0 mm (±10%) or less, 2.9 mm (±10%) or less, 2.8 mm(±10%) or less, 2.7 mm (±10%) or less, 2.6 mm (±10%) or less, 2.5 mm(±10%), 2.4 mm (±10%) or less, 2.3 mm (±10%) or less, 2.2 mm (±10%) orless, 2.1 mm (±10%) or less, 2.0 mm (±10%), 1.9 mm (±10%) or less, 1.8mm (±10%) or less, 1.7 mm (±10%) or less, 1.6 mm (±10%) or less, 1.5 mm(±10%), 1.4 mm (±10%) or less, 1.3 mm (±10%) or less, 1.2 mm (±10%) orless, 1.1 mm (±10%) or less, or 1.0 mm (±10%) or less. A flame barcomprising the composition may demonstrate a high probability of firsttime pass (pFTP) of the UL94 V0 test at a thickness of: 3.0 mm (±10%) orless, 2.9 mm (±10%) or less, 2.8 mm (±10%) or less, 2.7 mm (±10%) orless, 2.6 mm (±10%) or less, 2.5 mm (±10%), 2.4 mm (±10%) or less, 2.3mm (±10%) or less, 2.2 mm (±10%) or less, 2.1 mm (±10%) or less, 2.0 mm(±10%), 1.9 mm (±10%) or less, 1.8 mm (±10%) or less, 1.7 mm (±10%) orless, 1.6 mm (±10%) or less, 1.5 mm (±10%), 1.4 mm (±10%) or less, 1.3mm (±10%) or less, 1.2 mm (±10%) or less, 1.1 mm (±10%) or less, or 1.0mm (±10%) or less.

A material comprising the composition may be UL94 5VA compliant. Aplaque comprising the composition may achieve a UL94 5VA rating. Aplaque comprising the composition, optionally in the absence of abrominated and/or chlorinated flame retardant, may achieve a UL94 5VArating at a thickness of: 3.0 mm (±10%) or less, 2.9 mm (±10%) or less,2.8 mm (±10%) or less, 2.7 mm (±10%) or less, 2.6 mm (±10%) or less, 2.5mm (±10%), 2.4 mm (±10%) or less, 2.3 mm (±10%) or less, 2.2 mm (±10%)or less, 2.1 mm (±10%) or less, 2.0 mm (±10%), 1.9 mm (±10%) or less,1.8 mm (±10%) or less, 1.7 mm (±10%) or less, 1.6 mm (±10%) or less, 1.5mm (±10%), 1.4 mm (±10%) or less, 1.3 mm (±10%) or less, 1.2 mm (±10%)or less, 1.1 mm (±10%) or less, or 1.0 mm (±10%) or less.

A material comprising the composition may be transparent. A plaquecomprising the composition may have a transparency of: 70% or greater,71% or greater, 72% or greater, 73% or greater, 74% or greater, 75% orgreater, 76% or greater, 77% or greater, 78% or greater, 79% or greater,80% or greater, 81% or greater, 82% or greater, 83% or greater, 84% orgreater, 85% or greater, 86% or greater, 87% or greater, 88% or greater,89% or greater, 90% or greater, 91% or greater, 92% or greater, 93% orgreater, 94% or greater, 95% or greater, 96% or greater, 97% or greater,98% or greater, 99% or greater, 99.1 or greater, 99.2 or greater, 99.3or greater, 99.4 or greater, 99.5 or greater, 99.6 or greater, 99.7 orgreater, 99.8 or greater, 99.9 or greater, or 100%. The transparency maybe measured according to ASTM-D1003-00 at a thickness of 2.0 mm, 2.2 mm,2.4 mm, 2.6 mm, 2.8 mm, 3.0 mm, 3.2 mm, 3.4 mm, 3.6 mm, 3.8 mm, or 4.0mm.

A plaque comprising the composition may have a transparency of: 70% to100%, 70% to 99%, 70% to 98%, 70% to 97%, 70% to 96%, 70% to 95%, 70% to94%, 70% to 93%, 70% to 92%, 70% to 91%, 70% to 90%, 75% to 100%, 75% to99%, 75% to 98%, 75% to 97%, 75% to 96%, 75% to 95%, 75% to 94%, 75% to93%, 75% to 92%, 75% to 91%, 75% to 90%, 80% to 100%, 80% to 99%, 80% to98%, 80% to 97%, 80% to 96%, 80% to 95%, 80% to 94%, 80% to 93%, 80% to92%, 80% to 91%, 80% to 90%, 85% to 100%, 85% to 99%, 85% to 98%, 85% to97%, 85% to 96%, 85% to 95%, 85% to 94%, 85% to 93%, 85% to 92%, 85% to91%, 85% to 90%, 90% to 100%, 90% to 99%, 90% to 98%, 90% to 97%, 90% to96%, 90% to 95%, 90% to 94%, 90% to 93%, 90% to 92%, 90% to 91%, 91% to100%, 92% to 100%, 93% to 100%, 94% to 100%, 95% to 100%, 96% to 100%,97% to 100%, 98% to 100%, or 99% to 100%. The transparency may bemeasured according to ASTM-D1003-00 at a thickness of 2.0 mm, 2.2 mm,2.4 mm, 2.6 mm, 2.8 mm, 3.0 mm, 3.2 mm, 3.4 mm, 3.6 mm, 3.8 mm, or 4.0mm.

A plaque comprising the composition may have a haze value of: less than10%, less than 9%, less than 8%, less than 7%, less than 6%, less than5%, less than 4%, less than 3%, less than 2%, or less than 1%. A plaquecomprising the composition may have a haze value of: about 0% to about10%, about 0% to about 9%, about 0% to about 8%, about 0% to about 7%,about 0% to about 6%, about 0% to about 5%, about 0% to about 4%, about0% to about 3%, about 0% to about 2%, about 0% to about 1%, about 1% toabout 10%, about 2% to about 10%, about 3% to about 10%, about 4% toabout 10%, about 5% to about 10%, about 6% to about 10%, about 7% toabout 10%, about 8% to about 10%, or about 9% to about 10%. The hazevalue may be measured according to ASTM D1003-00 at a thickness of 2.0mm, 2.2 mm, 2.4 mm, 2.6 mm, 2.8 mm, 3.0 mm, 3.2 mm, 3.4 mm, 3.6 mm, 3.8mm, or 4.0 mm.

An ASTM part comprising the composition may have full ductility undermultiaxial impact test conditions per ASTM D3763 at −30° C. determinedusing a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thick disk sample,½-inch (12.7 mm) diameter dart, and an impact velocity of 3.3 meters persecond (m/s).

A material comprising the composition may exhibit extreme chemicalresistance (e.g., resistance to cracking or shrinking upon exposure to asolvent such as acetone or toluene). An ASTM part comprising thecomposition may have an elongation at break of at least 100% afterexposure to acetone under 1% strain.

A material comprising the composition may contain an insoluble methylenechloride insoluble fraction. The material may contain at least 5 wt % ofan insoluble methylene chloride fraction in a 1 mm thick film.

The compositions comprising a cross-linked polycarbonate may have aweight average molecular weight (Mw) of about 18,000 to about 200,000Daltons [^(±)1,000 Daltons], of about 25,000 to about 120,000 Daltons[^(±)1,000 Daltons], of about 30,000 to about 100,000 Daltons [^(±)1,000Daltons], or of about 35,000 to about 80,000 Daltons [^(±)1,000Daltons]. In certain embodiments, the cross-linked polycarbonates haveweight average molecular weights of about 22,000 Daltons [^(±)1,000Daltons], about 23,000 Daltons [^(±)1,000 Daltons], about 24,000 Daltons[^(±)1,000 Daltons], about 25,000 Daltons [^(±)1,000 Daltons], about26,000 Daltons [^(±)1,000 Daltons], about 27,000 Daltons [^(±)1,000Daltons], about 28,000 Daltons [^(±)1,000 Daltons], about 29,000 Daltons[^(±)1,000 Daltons], about 30,000 Daltons [^(±)1,000 Daltons], about31,000 Daltons [^(±)1,000 Daltons], about 32,000 Daltons [^(±)1,000Daltons], about 33,000 Daltons [^(±)1,000 Daltons], about 34,000 Daltons[^(±)1,000 Daltons], about 35,000 Daltons [^(±)1,000 Daltons], about36,000 Daltons [^(±)1,000 Daltons], about 37,000 Daltons [^(±)1,000Daltons], about 38,000 Daltons [^(±)1,000 Daltons], about 39,000 Daltons[^(±)1,000 Daltons], about 40,000 Daltons [^(±)1,000 Daltons], about41,000 Daltons [^(±)1,000 Daltons], about 42,000 Daltons [^(±)1,000Daltons], about 43,000 Daltons [^(±)1,000 Daltons], about 44,000 Daltons[^(±)1,000 Daltons], about 45,000 Daltons [^(±)1,000 Daltons], about46,000 Daltons [^(±)1,000 Daltons], about 47,000 Daltons [^(±)1,000Daltons], about 48,000 Daltons [^(±)1,000 Daltons], about 49,000 Daltons[^(±)1,000 Daltons], about 50,000 Daltons [^(±)1,000 Daltons], about51,000 Daltons [^(±)1,000 Daltons], about 52,000 Daltons [^(±)1,000Daltons], about 53,000 Daltons [^(±)1,000 Daltons], about 54,000 Daltons[^(±)1,000 Daltons], about 55,000 Daltons [^(±)1,000 Daltons], about56,000 Daltons [^(±)1,000 Daltons], about 57,000 Daltons [^(±)1,000Daltons], about 58,000 Daltons [^(±)1,000 Daltons], about 59,000 Daltons[^(±)1,000 Daltons], about 60,000 Daltons [^(±)1,000 Daltons], about61,000 Daltons [^(±)1,000 Daltons], about 62,000 Daltons [^(±)1,000Daltons], about 63,000 Daltons [^(±)1,000 Daltons], about 64,000 Daltons[^(±)1,000 Daltons], about 65,000 Daltons [^(±)1,000 Daltons], about66,000 Daltons [^(±)1,000 Daltons], about 67,000 Daltons [^(±)1,000Daltons], about 68,000 Daltons [^(±)1,000 Daltons], about 69,000 Daltons[^(±)1,000 Daltons], about 70,000 Daltons [^(±)1,000 Daltons], about71,000 Daltons [^(±)1,000 Daltons], about 72,000 Daltons [^(±)1,000Daltons], about 73,000 Daltons [^(±)1,000 Daltons], about 74,000 Daltons[^(±)1,000 Daltons], about 75,000 Daltons [^(±)1,000 Daltons], about76,000 Daltons [^(±)1,000 Daltons], about 77,000 Daltons [^(±)1,000Daltons], about 78,000 Daltons [^(±)1,000 Daltons], about 79,000 Daltons[^(±)1,000 Daltons], about 80,000 Daltons [^(±)1,000 Daltons], about81,000 Daltons [^(±)1,000 Daltons], about 82,000 Daltons [^(±)1,000Daltons], about 83,000 Daltons [^(±)1,000 Daltons], about 84,000 Daltons[^(±)1,000 Daltons], about 85,000 Daltons [^(±)1,000 Daltons], about86,000 Daltons [^(±)1,000 Daltons], about 87,000 Daltons [^(±)1,000Daltons], about 88,000 Daltons [^(±)1,000 Daltons], about 89,000 Daltons[^(±)1,000 Daltons], about 90,000 Daltons [^(±)1,000 Daltons], about91,000 Daltons [^(±)1,000 Daltons], about 92,000 Daltons [^(±)1,000Daltons], about 93,000 Daltons [^(±)1,000 Daltons], about 94,000 Daltons[^(±)1,000 Daltons], about 95,000 Daltons [^(±)1,000 Daltons], about96,000 Daltons [^(±)1,000 Daltons], about 97,000 Daltons [^(±)1,000Daltons], about 98,000 Daltons [^(±)1,000 Daltons], about 99,000 Daltons[^(±)1,000 Daltons], about 100,000 Daltons [^(±)1,000 Daltons], about101,000 Daltons [^(±)1,000 Daltons], about 102,000 Daltons [^(±)1,000Daltons], about 103,000 Daltons [^(±)1,000 Daltons], about 104,000Daltons [^(±)1,000 Daltons], about 105,000 Daltons [^(±)1,000 Daltons],about 106,000 Daltons [^(±)1,000 Daltons], about 107,000 Daltons[^(±)1,000 Daltons], about 108,000 Daltons [^(±)1,000 Daltons], about109,000 Daltons [^(±)1,000 Daltons], about 110,000 Daltons [^(±)1,000Daltons], about 111,000 Daltons [^(±)1,000 Daltons], about 112,000Daltons [^(±)1,000 Daltons], about 113,000 Daltons [^(±)1,000 Daltons],about 114,000 Daltons [^(±)1,000 Daltons], about 115,000 Daltons[^(±)1,000 Daltons], about 116,000 Daltons [^(±)1,000 Daltons], about117,000 Daltons [^(±)1,000 Daltons], about 118,000 Daltons [^(±)1,000Daltons], about 119,000 Daltons [^(±)1,000 Daltons], about 120,000Daltons [^(±)1,000 Daltons], about 121,000 Daltons [^(±)1,000 Daltons],about 122,000 Daltons [^(±)1,000 Daltons], about 123,000 Daltons[^(±)1,000 Daltons], about 124,000 Daltons [^(±)1,000 Daltons], or about125,000 Daltons [^(±)1,000 Daltons]. Molecular weight determinations maybe performed using gel permeation chromatography (GPC), using across-linked styrene-divinylbenzene column and calibrated topolycarbonate references using a UV-VIS detector set at 264 nm. Samplesmay be prepared at a concentration of about 1 mg/ml, and eluted at aflow rate of about 1.0 ml/min.

(A) Cross-Linkable Polycarbonates

The compositions comprising a cross-linked polycarbonate are derivedfrom one or more cross-linkable polycarbonates (also referred to as“non-cross-linked polycarbonates”), said cross-linkable polycarbonatescomprising a monohydroxybenzophenone derived endcap content. Thecross-linkable polycarbonates may comprise about 0.5 mol % to about 5mol % endcap groups derived from a monohydroxybenzophenone, about 1 mol% to about 3 mol % endcap groups derived from a monohydroxybenzophenone,about 1.7 mol % to about 2.5 mol % endcap groups derived from amonohydroxybenzophenone, about 2 mol % to about 2.5 mol % endcap groupsderived from a monohydroxybenzophenone, or about 2.5 mol % to about 3.0mol % endcap groups derived from a monohydroxybenzophenone. Thecross-linkable polycarbonates may have a monohydroxybenzophenone derivedendcap content of: 0.5 mol %, 0.6 mol %, 0.7 mol %, 0.8 mol %, 0.9 mol%, 1.0 mol %, 1.1 mol %, 1.2 mol %, 1.3 mol %, 1.4 mol %, 1.5 mol %, 1.6mol %, 1.7 mol %, 1.8 mol %, 1.9 mol %, 2.0 mol %, 2.1 mol %, 2.2 mol %,2.3 mol %, 2.4 mol %, 2.5 mol %, 2.6 mol %, 2.7 mol %, 2.8 mol %, 2.9mol %, 3.0 mol %, 3.1 mol %, 3.2 mol %, 3.3 mol %, 3.4 mol %, 3.5 mol %,3.6 mol %, 3.7 mol %, 3.8 mol %, 3.9 mol %, 4.0 mol %, 4.1 mol %, 4.2mol %, 4.3 mol %, 4.4 mol %, 4.5 mol %, 4.6 mol %, 4.7 mol %, 4.8 mol %,4.9 mol %, or 5.0 mol %.

The cross-linkable polycarbonates disclosed herein may be cross-linkedusing a variety of cross-linking methods. In certain embodiments, thepolycarbonates may be cross-linked by exposure to ultra-violet (UV)radiation. In certain embodiments, the polycarbonates may becross-linked by exposure to radiation emitted by the sun (e.g.,UV-radiation). In certain embodiments, the polycarbonates may becross-linked by exposure to an electron beam. In certain embodiments,the polycarbonates are not cross-linked using gamma radiation. Incertain embodiments, the polycarbonates cannot be cross-linked usinggamma radiation. In certain embodiments, the polycarbonates are notcross-linked using an electron beam. In certain embodiments, thepolycarbonates cannot be cross-linked using an electron beam.

The cross-linkable polycarbonates may be cross-linked using any suitabledosage of UV-radiation and any suitable radiation source. In certainembodiments, the cross-linkable polycarbonates are cross-linked byexposing the polycarbonates to a dosage of UV-radiation. The appropriatedose maybe obtained by one or multiple passes under a UV source or by asingle pass through a chamber with multiple UV sources or anycombination thereof. It may also be advangteous to cross-link thepolycarbonates by exposing the polycarbonates to the sun.

In certain embodiments, the polycarbonates are cross-linked by exposureto UV-radiation from a 9 mm D bulb from Fusion UV systems, Inc., havingoutput specifications of about 796.5 Watts from 201 nm to 600 nm. Incertain embodiments, the polycarbonates are cross-linked by exposure toUV-radiation from a 9 mm D bulb having out specifications of 505 Wattsfrom 201 nm to 400 nm, 657 Watts from 201 nm to 450 nm, 291 Watts from401 nm to 600 nm, and/or 35 Watts from 601 nm to 850 nm.

In certain embodiments, the polycarbonates are cross-linked by passingthe polycarbonates through a UV-oven or under a UV-lamp one or moretimes. In certain embodiments, a material comprising the cross-linkablepolycarbonate is passed through a UV-oven or under a UV-lamp or bank ofUV-lamps 1 to 10 times, 2 to 8 times, or 3 to 6 times. In certainembodiments, a material comprising the polycarbonate is passed through aUV-oven or under a UV-lamp one time, two times, three times, four times,or five times.

In certain embodiments, the polycarbonates are cross-linked by sunexposure. In certain embodiments, the polycarbonates are cross-linked bysun exposure for a time period greater than zero hours. In certainembodiments, the polycarbonates are cross-linked by sun exposure for atime period greater than or equal to four hours. In certain embodiments,the polycarbonates are cross-linked by sun exposure for a time periodgreater than or equal to twenty-four hours. In certain embodiments, thepolycarbonates are cross-linked by sun exposure for a time periodgreater than or equal to forty-eight hours. In certain embodiments, thepolycarbonates are cross-linked by sun exposure for a time periodgreater than or equal to seventy-two hours. In certain embodiments, thepolycarbonates are cross-linked by sun exposure for a time periodgreater than or equal to one-hundred forty-four hours. In certainembodiments, the polycarbonates are cross-linked by sun exposure for atime period greater than or equal to three-hundred sixty hours. Incertain embodiments, the polycarbonates are cross-linked by sun exposurefor a time period ranging from about 4 hours to about 360 hours. Incertain embodiments, the polycarbonates are cross-linked by sun exposurefor a time period of about 4 hours, about 24 hours, about 48 hours,about 72 hours, about 144 hours, or about 360 hours.

Cross-linking may be affected to a desired depth of a materialcomprising the cross-linkable polycarbonates, such as an articleinjection-molded from the cross-linkable polycarbonate. In certainembodiments, the depth of cross-linking, as measured from an outersurface of the material, may be 30 microns or less, 25 microns or less,20 microns or less, 15 microns or less, 10 microns or less, or 5 micronsor less. In certain embodiments, the depth of cross-linking, as measuredfrom an outer surface of the material, may be 30 microns or less, 29microns or less, 28 microns or less, 27 microns or less, 26 microns orless, 25 microns or less, 24 microns or less, 23 microns or less, 22microns or less, 21 microns or less, 20 microns or less, 19 microns orless, 18 microns or less, 17 microns or less, 16 microns or less, 15microns or less, 14 microns or less, 13 microns or less, 12 microns orless, 11 microns or less, 10 microns or less, 9 microns or less, 8microns or less, 7 microns or less, 6 microns or less, 5 microns orless, 4 microns or less, 3 microns or less, 2 microns or less, or 1micron or less. The depth of cross-linking can be determined by fieldemission microscopy or by FTIR by the loss of the benzophenone ketone,for example.

The depth of cross-linking can be attenuated by the dosage ofUV-radiation. Other factors that may effect the depth of cross-linkinginclude structural variation of the polycarbonate comprising themonohydroxybenzophenone endcap, the nature of the other components thatmay be in the composition to be cross-linked, and the method ofcross-linking and variables associated therewith.

The cross-linkable polycarbonates of the invention includehomopolycarbonates, copolymers comprising different moieties in thecarbonate (referred as “copolycarbonates”), copolymers comprisingcarbonate units and other types of polymer units such as polyesterunits, polysiloxane units, and combinations comprising at least onehomopolycarbonate and copolycarbonate.

The cross-linkable polycarbonate may thus comprise identical ordifferent repeating units derived from one or more monomers (e.g. asecond, third, fourth, fifth, sixth, etc., other monomer compound). Themonomers of the cross-linkable polycarbonate may be randomlyincorporated into the polycarbonate. For example, a cross-linkablepolycarbonate copolymer of the invention may be arranged in analternating sequence following a statistical distribution, which isindependent of the mole ratio of the structural units present in thepolymer chain. A random cross-linkable polycarbonate copolymer may havea structure, which can be indicated by the presence of several blocksequences (I-I) and (O-O) and alternate sequences (I-O) or (O-I), thatfollow a statistical distribution. In a random x:(1-x) copolymer,wherein x is the mole percent of a first monomer(s) and 1-x is the molepercent of the monomers, one can calculate the distribution of eachmonomer using peak area values determined by ¹³C NMR, for example.

A cross-linkable polycarbonate copolymer of the invention may havealternating I and O units (-I-O-I-O-I-O-I-O-), or I and O units arrangedin a repeating sequence (e.g. a periodic copolymer having the formula:(I-O-I-O-O-I-I-I-I-O-O-O)n). The cross-linkable polycarbonate copolymermay be a statistical copolymer in which the sequence of monomer residuesfollows a statistical rule. For example, if the probability of finding agiven type monomer residue at a particular point in the chain is equalto the mole fraction of that monomer residue in the chain, then thepolymer may be referred to as a truly random copolymer. Thecross-linkable polycarbonate copolymer may be a block copolymer thatcomprises two or more homopolymer subunits linked by covalent bonds(-I-I-I-I-I-O-O-O-O-O-). The union of the homopolymer subunits mayrequire an intermediate non-repeating subunit, known as a junctionblock. Block copolymers with two or three distinct blocks are calleddiblock copolymers and triblock copolymers, respectively.

The cross-linkable polycarbonates of the invention may include anysuitable mole % of selected monomer units, with the proviso that thepolycarbonates comprise a mol % (e.g., about 0.5 mol % to about 5 mol %)of endcap groups derived from a monohydroxybenzophenone. The polymersmay comprise about 1% to about 99.5%, about 5% to about 95%, about 10%to about 90%, about 15% to about 85%, about 20% to about 80%, about 25%to about 75%, about 30% to about 70%, about 35% to about 65%, about 40%to about 60%, or about 45% to about 55% mole % of a selected monomerunit.

The cross-linkable polycarbonates of the invention may have a glasstransition temperature (Tg) of greater than 120° C., 125° C., 130° C.,135° C., 140° C., 145° C., 150° C., 155° C., 160° C., 165° C., 170° C.,175° C., 180° C., 185° C., 190° C., 200° C., 210° C., 220° C., 230° C.,240° C., 250° C., 260° C., 270° C., 280° C., 290° C., or 300° C., asmeasured using a differential scanning calorimetry method. In certainembodiments, the polycarbonates have glass transition temperaturesranging from about 120° C. to about 230° C., about 140° C. to about 160°C., about 145° C. to about 155° C., about 148° C. to about 152° C., orabout 149° C. to about 151° C. In certain embodiments, thepolycarbonates have glass transition temperatures of 149.0° C., 149.1°C., 149.2° C., 149.3° C., 149.4° C., 149.5° C., 149.6° C., 149.7° C.,149.8° C., 149.9° C., 150.0° C., 150.1° C., 150.2° C., 150.3° C., 150.4°C., 150.5° C., 150.6° C., 150.7° C., 150.8° C., 150.9° C., 151.0° C.,151.1° C., 151.2° C., 151.3° C., 151.4° C., 151.5° C., 151.6° C., 151.7°C., 151.8° C., 151.9° C., 152.0° C., 152.1° C., 152.2° C., 152.3° C.,152.4° C., 152.5° C., 152.6° C., 152.7° C., 152.8° C., 152.9° C., or153.0° C.

The cross-linkable polycarbonates of the invention may have a weightaverage molecular weight (Mw) of about 1,500 to about 150,000 Daltons[^(±)1,000 Daltons], of about 10,000 to about 50,000 Daltons [^(±)1,000Daltons], of about 15,000 to about 35,000 Daltons [^(±)1,000 Daltons],or of about 20,000 to about 30,000 Daltons [^(±)1,000 Daltons]. Incertain embodiments, the cross-linkable polycarbonates have weightaverage molecular weights of about 15,000 Daltons [^(±)1,000 Daltons],about 16,000 Daltons [^(±)1,000 Daltons], about 17,000 Daltons[^(±)1,000 Daltons], about 18,000 Daltons [^(±)1,000 Daltons], about19,000 Daltons [^(±)1,000 Daltons], about 20,000 Daltons [^(±)1,000Daltons], about 21,000 Daltons [^(±)1,000 Daltons], about 22,000 Daltons[^(±)1,000 Daltons], about 23,000 Daltons [^(±)1,000 Daltons], about24,000 Daltons [^(±)1,000 Daltons], about 25,000 Daltons [^(±)1,000Daltons], about 26,000 Daltons [^(±)1,000 Daltons], about 27,000 Daltons[^(±)1,000 Daltons], about 28,000 Daltons [^(±)1,000 Daltons], about29,000 Daltons [^(±)1,000 Daltons], about 30,000 Daltons [^(±)1,000Daltons], about 31,000 Daltons [^(±)1,000 Daltons], about 32,000 Daltons[^(±)1,000 Daltons], about 33,000 Daltons [^(±)1,000 Daltons], about34,000 Daltons [^(±)1,000 Daltons], or about 35,000 Daltons [^(±)1,000Daltons]. Molecular weight determinations may be performed using gelpermeation chromatography (GPC), using a cross-linkedstyrene-divinylbenzene column and calibrated to polycarbonate referencesusing a UV-VIS detector set at 264 nm. Samples may be prepared at aconcentration of about 1 mg/ml, and eluted at a flow rate of about 1.0ml/min.

The cross-linkable polycarbonates of the invention may have apolydispersity index (PDI) of about 1.0 to about 10.0, about 2.0 toabout 7.0, or about 3.0 to about 6.0. In certain embodiments, thepolycarbonates have PDIs of about 2.50, about 3.00, about 3.50, about4.00, about 4.50, about 5.00, about 5.50, about 6.00, about 6.50, about7.00, or about 7.50.

The cross-linkable polycarbonates of the invention may have a meltvolume flow rate (often abbreviated MVR), which measures the rate ofextrusion of a composition through an orifice at a prescribedtemperature and load. In certain embodiments, the polycarbonates mayhave an MVR of 2 to 70 cm³/10 min, 2 to 50 cm³/10 min, 2 to 40 cm³/10min, 2 to 30 cm³/10 min, 2 to 25 cm³/10 min, 2 to 20 cm³/10 min, 5 to 70cm³/10 min, 5 to 50 cm³/10 min, 5 to 40 cm³/10 min, 5 to 30 cm³/10 min,5 to 25 cm³/10 min, 5 to 20 cm³/10 min, 10 to 170 cm³/10 min, 10 to 50cm³/10 min, 10 to 40 cm³/10 min, 10 to 30 cm³/10 min, 10 to 25 cm³/10min, or 10 to 20 cm³/10 min, using the ASTM D1238 method, 1.2 kg load,300° C. temperature, 360 second dwell. In certain embodiments, thepolycarbonates may have an MVR measured using the ASTM D1238 method, 1.2kg load, 300° C. temperature, 360 second dwell, of: 2.0 cm³/10 min, 2.1cm³/10 min, 2.2 cm³/10 min, 2.3 cm³/10 min, 2.4 cm³/10 min, 2.5 cm³/10min, 2.6 cm³/10 min, 2.7 cm³/10 min, 2.8 cm³/10 min, 2.9 cm³/10 min, 3.0cm³/10 min, 3.1 cm³/10 min, 3.2 cm³/10 min, 3.3 cm³/10 min, 3.4 cm³/10min, 3.5 cm³/10 min, 3.6 cm³/10 min, 3.7 cm³/10 min, 3.8 cm³/10 min, 3.9cm³/10 min, 4.0 cm³/10 min, 4.1 cm³/10 min, 4.2 cm³/10 min, 4.3 cm³/10min, 4.4 cm³/10 min, 4.5 cm³/10 min, 4.6 cm³/10 min, 4.7 cm³/10 min, 4.8cm³/10 min, 4.9 cm³/10 min, 5.0 cm³/10 min, 5.1 cm³/10 min, 5.2 cm³/10min, 5.3 cm³/10 min, 5.4 cm³/10 min, 5.5 cm³/10 min, 5.6 cm³/10 min, 5.7cm³/10 min, 5.8 cm³/10 min, 5.9 cm³/10 min, 6.0 cm³/10 min, 6.1 cm³/10min, 6.2 cm³/10 min, 6.3 cm³/10 min, 6.4 cm³/10 min, 6.5 cm³/10 min, 6.6cm³/10 min, 6.7 cm³/10 min, 6.8 cm³/10 min, 6.9 cm³/10 min, 7.0 cm³/10min, 7.1 cm³/10 min, 7.2 cm³/10 min 7.3 cm³/10 min, 7.4 cm³/10 min, 7.5cm³/10 min, 7.6 cm³/10 min, 7.7 cm³/10 min, 7.8 cm³/10 min, 7.9 cm³/10min, 8.0 cm³/10 min, 8.1 cm³/10 min, 8.2 cm³/10 min, 8.3 cm³/10 min, 8.4cm³/10 min, 8.5 cm³/10 min, 8.6 cm³/10 min, 8.7 cm³/10 min, 8.8 cm³/10min, 8.9 cm³/10 min, 9.0 cm³/10 min, 9.1 cm³/10 min, 9.2 cm³/10 min, 9.3cm³/10 min, 9.4 cm³/10 min, 9.5 cm³/10 min, 9.6 cm³/10 min, 9.7 cm³/10min, 9.8 cm³/10 min, 9.9 cm³/10 min, 10.0 cm³/10 min, 10.1 cm³/10 min,10.2 cm³/10 min, 10.3 cm³/10 min, 10.4 cm³/10 min, 10.5 cm³/10 min, 10.6cm³/10 min, 10.7 cm³/10 min, 10.8 cm³/10 min, 10.9 cm³/10 min, 11.0cm³/10 min, 11.1 cm³/10 min, 11.2 cm³/10 min, 11.3 cm³/10 min, 11.4cm³/10 min, 11.5 cm³/10 min, 11.6 cm³/10 min, 11.7 cm³/10 min, 11.8cm³/10 min, 11.9 cm³/10 min, 12.0 cm³/10 min, 12.1 cm³/10 min, 12.2cm³/10 min, 12.3 cm³/10 min, 12.4 cm³/10 min, 12.5 cm³/10 min, 12.6cm³/10 min, 12.7 cm³/10 min, 12.8 cm³/10 min, 12.9 cm³/10 min, 13.0cm³/10 min, 13.1 cm³/10 min, 13.2 cm³/10 min, 13.3 cm³/10 min, 13.4cm³/10 min, 13.5 cm³/10 min, 13.6 cm³/10 min, 13.7 cm³/10 min, 13.8cm³/10 min, 13.9 cm³/10 min, 14.0 cm³/10 min, 14.1 cm³/10 min, 14.2cm³/10 min, 14.3 cm³/10 min, 14.4 cm³/10 min. 14.5 cm³/10 min, 14.6cm³/10 min, 14.7 cm³/10 min, 14.8 cm³/10 min, 14.9 cm³/10 min, 15.0cm³/10 min, 15.1 cm³/10 min, 15.2 cm³/10 min, 15.3 cm³/10 min, 15.4cm³/10 min, 15.5 cm³/10 min, 15.6 cm³/10 min, 15.7 cm³/10 min, 15.8cm³/10 min, 15.9 cm³/10 min, 16.0 cm³/10 min, 16.1 cm³/10 min, 16.2cm³/10 min, 16.3 cm³/10 min, 16.4 cm³/10 min, 16.5 cm³/10 min, 16.6cm³/10 min, 16.7 cm³/10 min, 16.8 cm³/10 min, 16.9 cm³/10 min, 17.0cm³/10 min, 17.1 cm³/10 min, 17.2 cm³/10 min, 17.3 cm³/10 min, 17.4cm³/10 min, 17.5 cm³/10 min, 17.6 cm³/10 min, 17.7 cm³/10 min, 17.8cm³/10 min, 17.9 cm³/10 min, 18.0 cm³/10 min, 18.1 cm³/10 min, 18.2cm³/10 min, 18.3 cm³/10 min, 18.4 cm³/10 min, 18.5 cm³/10 min, 18.6cm³/10 min 18.7 cm³/10 min, 18.8 cm³/10 min, 18.9 cm³/10 min, 19.0cm³/10 min, 19.1 cm³/10 min, 19.2 cm³/10 min, 19.3 cm³/10 min, 19.4cm³/10 min, 19.5 cm³/10 min, 19.6 cm³/10 min, 19.7 cm³/10 min, 19.8cm³/10 min, 19.9 cm³/10 min, 20.0 cm³/10 min, 20.1 cm³/10 min, 20.2cm³/10 min, 20.3 cm³/10 min, 20.4 cm³/10 min, 20.5 cm³/10 min, 20.6cm³/10 min, 20.7 cm³/10 min, 20.8 cm³/10 min, 20.9 cm³/10 min, 21.0cm³/10 min, 21.1 cm³/10 min, 21.2 cm³/10 min, 21.3 cm³/10 min, 21.4cm³/10 min, 21.5 cm³/10 min, 21.6 cm³/10 min, 21.7 cm³/10 min, 21.8cm³/10 min, 21.9 cm³/10 min, 22.0 cm³/10 min, 22.1 cm³/10 min, 22.2cm³/10 min, 22.3 cm³/10 min, 22.4 cm³/10 min, 22.5 cm³/10 min, 22.6cm³/10 min, 22.7 cm³/10 min, 22.8 cm³/10 min, 22.9 cm³/10 min, 23.0cm³/10 min, 23.1 cm³/10 min, 23.2 cm³/10 min, 23.3 cm³/10 min, 23.4cm³/10 min, 23.5 cm³/10 min, 23.6 cm³/10 min, 23.7 cm³/10 min, 23.8cm³/10 min, 23.9 cm³/10 min, 24.0 cm³/10 min, 24.1 cm³/10 min, 24.2cm³/10 min, 24.3 cm³/10 min, 24.4 cm³/10 min, 24.5 cm³/10 min, 24.6cm³/10 min, 24.7 cm³/10 min, 24.8 cm³/10 min, 24.9 cm³/10 min, 25.0cm³/10 min, 25.1 cm³/10 min, 25.2 cm³/10 min, 25.3 cm³/10 min, 25.4cm³/10 min, 25.5 cm³/10 min, 25.6 cm³/10 min, 25.7 cm³/10 min, 25.8cm³/10 min, 25.9 cm³/10 min, 26.0 cm³/10 min, 26.1 cm³/10 min, 26.2cm³/10 min, 26.3 cm³/10 min, 26.4 cm³/10 min, 26.5 cm³/10 min, 26.6cm³/10 min, 26.7 cm³/10 min, 26.8 cm³/10 min, 26.9 cm³/10 min, 27.0cm³/10 min, 27.1 cm³/10 min, 27.2 cm³/10 min, 27.3 cm³/10 min, 27.4cm³/10 min, 27.5 cm³/10 min, 27.6 cm³/10 min, 27.7 cm³/10 min, 27.8cm³/10 min, 27.9 cm³/10 min, 28.0 cm³/10 min, 28.1 cm³/10 min, 28.2cm³/10 min, 28.3 cm³/10 min, 28.4 cm³/10 min, 28.5 cm³/10 min, 28.6cm³/10 min, 28.7 cm³/10 min, 28.8 cm³/10 min, 28.9 cm³/10 min, 29.0cm³/10 min, 29.1 cm³/10 min, 29.2 cm³/10 min, 29.3 cm³/10 min, 29.4cm³/10 min, 29.5 cm³/10 min, 29.6 cm³/10 min, 29.7 cm³/10 min, 29.8cm³/10 min, 29.9 cm³/10 min, 30.0 cm³/10 min, 30.1 cm³/10 min, 30.2cm³/10 min, 30.3 cm³/10 min, 30.4 cm³/10 min, 30.5 cm³/10 min, 30.6cm³/10 min, 30.7 cm³/10 min, 30.8 cm³/10 min, 30.9 cm³/10 min, 31.0cm³/10 min, 31.1 cm³/10 min, 31.2 cm³/10 min, 31.3 cm³/10 min, 31.4cm³/10 min, 31.5 cm³/10 min, 31.6 cm³/10 min, 31.7 cm³/10 min, 31.8cm³/10 min, 31.9 cm³/10 min, 32.0 cm³/10 min, 32.1 cm³/10 min, 32.2cm³/10 min, 32.3 cm³/10 min, 32.4 cm³/10 min, 32.5 cm³/10 min, 32.6cm³/10 min, 32.7 cm³/10 min, 32.8 cm³/10 min, 32.9 cm³/10 min, 33.0cm³/10 min, 33.1 cm³/10 min, 33.2 cm³/10 min, 33.3 cm³/10 min, 33.4cm³/10 min, 33.5 cm³/10 min, 33.6 cm³/10 min, 33.7 cm³/10 min, 33.8cm³/10 min, 33.9 cm³/10 min, 34.0 cm³/10 min, 34.1 cm³/10 min, 34.2cm³/10 min, 34.3 cm³/10 min, 34.4 cm³/10 min, 34.5 cm³/10 min, 34.6cm³/10 min, 34.7 cm³/10 min, 34.8 cm³/10 min, 34.9 cm³/10 min, or 35.0cm³/10 min.

The cross-linkable polycarbonates of the invention may have a biocontentof 2 weight % to 90 weight %; 5 weight % to 25 weight %; 10 weight % to30 weight %; 15 weight % to 35 weight %; 20 weight % to 40 weight %; 25weight % to 45 weight %; 30 weight % to 50 weight %; 35 weight % to 55weight %; 40 weight % to 60 weight %; 45 weight % to 65 weight %; 55weight % to 70% weight %; 60 weight % to 75 weight %; 50 weight % to 80weight %; or 50 weight % to 90 weight %. The biocontent may be measuredaccording to ASTM D6866.

The cross-linkable polycarbonates of the invention may have a modulus ofelasticity of greater than or equal to 2200 megapascals (MPa), greaterthan or equal to 2310 MPa, greater than or equal to 2320 MPa, greaterthan or equal to 2330 MPa, greater than or equal to 2340 MPa, greaterthan or equal to 2350 MPa, greater than or equal to 2360 MPa, greaterthan or equal to 2370 MPa, greater than or equal to 2380 MPa, greaterthan or equal to 2390 MPa, greater than or equal to 2400 MPa, greaterthan or equal to 2420 MPa, greater than or equal to 2440 MPa, greaterthan or equal to 2460 MPa, greater than or equal to 2480 MPa, greaterthan or equal to 2500 MPa, or greater than or equal to 2520 MPa asmeasured by ASTM D 790 at 1.3 mm/min, 50 mm span.

In an embodiment the cross-linkable polycarbonates of the invention mayhave a flexural modulus of 2,200 to 2,500, preferably 2,250 to 2,450,more preferably 2,300 to 2,400 MPa.

In another embodiment the cross-linkable polycarbonates of the inventionmay have a flexural modulus of 2,300 to 2,600, preferably 2,400 to2,600, more preferably 2,450 to 2,550 MPa.

The cross-linkable polycarbonates of the invention may have a tensilestrength at break of greater than or equal to 60 megapascals (MPa),greater than or equal to 61 MPa, greater than or equal to 62 MPa,greater than or equal to 63 MPa, greater than or equal to 64 MPa,greater than or equal to 65 MPa, greater than or equal to 66 MPa,greater than or equal to 67 MPa, greater than or equal to 68 MPa,greater than or equal to 69 MPa, greater than or equal to 70 MPa,greater than or equal to 71 MPa, greater than or equal to 72 MPa,greater than or equal to 73 MPa, greater than or equal to 74 MPa,greater than or equal to 75 MPa as measured by ASTM D 638 Type I at 50mm/min.

The cross-linkable polycarbonates of the invention may possess aductility of greater than or equal to 60%, greater than or equal to 65%,greater than or equal to 70%, greater than or equal to 75%, greater thanor equal to 80%, greater than or equal to 85%, greater than or equal to90%, greater than or equal to 95%, or 100% in a notched izod test at−20° C., −15° C., −10° C., 0° C., 5° C., 10° C., 15° C., 20° C., 23° C.,25° C., 30° C., or 35° C. at a thickness of 3.2 mm according to ASTM D256-10.

The cross-linkable polycarbonates of the invention may have a notchedizod impact strength (NII) of greater than or equal to 500 J/m, greaterthan or equal to 550 J/m, greater than or equal to 600 J/m, greater thanor equal to 650 J/m, greater than or equal to 700 J/m, greater than orequal to 750 J/m, greater than or equal to 800 J/m, greater than orequal to 850 J/m, greater than or equal to 900 J/m, greater than orequal to 950 J/m, or greater than or equal to 1000 J/m, measured at 23°C. according to ASTM D 256.

The cross-linkable polycarbonates of the invention may have a heatdistortion temperature of greater than or equal to 110° C., 111° C.,112° C., 113° C., 114° C., 115° C., 116° C., 117° C., 118° C., 119° C.,120° C., 121° C., 122° C., 123° C., 124° C., 125° C., 126° C., 127° C.,128° C., 129° C., 130° C., 131° C., 132° C., 133° C., 134° C., 135° C.,136° C., 137° C., 138° C., 139° C., 140° C., 141° C., 142° C., 143° C.,144° C., 145° C., 146° C., 147° C., 148° C., 149° C., 150° C., 151° C.,152° C., 153° C., 154° C., 155° C., 156° C., 157° C., 158° C., 159° C.,160, 161° C., 162° C., 163° C., 164° C., 165° C., 166° C., 167° C., 168°C., 169° C., or 170° C., as measured according to ASTM D 648 at 1.82MPa, with 3.2 mm thick unannealed mm bar.

The cross-linkable polycarbonates of the invention may have a percenthaze value of less than or equal to 10.0%, less than or equal to 8.0%,less than or equal to 6.0%, less than or equal to 5.0%, less than orequal to 4.0%, less than or equal to 3.0%, less than or equal to 2.0%,less than or equal to 1.5%, less than or equal to 1.0%, or less than orequal to 0.5% as measured at a certain thickness according to ASTM D1003-07. The polycarbonate haze may be measured at a 2.0, 2.2, 2.4, 2.6,2.8, 3.0, 3.2, 3.4, 3.6, 3.8, or a 4.0 millimeter thickness. Thepolycarbonate may be measured at a 0.125 inch thickness. Thepolycarbonate may have a light transmittance greater than or equal to50%, greater than or equal to 60%, greater than or equal to 65%, greaterthan or equal to 70%, greater than or equal to 75%, greater than orequal to 80%, greater than or equal to 85%, greater than or equal to90%, greater than or equal to 95%, greater than or equal to 96%, greaterthan or equal to 97%, greater than or equal to 98%, greater than orequal to 99%, greater than or equal to 99.1%, greater than or equal to99.2%, greater than or equal to 99.3%, greater than or equal to 99.4%,greater than or equal to 99.5%, greater than or equal to 99.6%, greaterthan or equal to 99.7%, greater than or equal to 99.8%, or greater thanor equal to 99.9%, as measured at certain thicknesses according to ASTMD 1003-07. The polycarbonate transparency may be measured at a 2.0, 2.2,2.4, 2.6, 2.8, 3.0, 3.2, 3.4, 3.6, 3.8, or a 4.0 millimeter thickness.

In certain embodiments, the cross-linkable polycarbonates of theinvention do not include soft block or soft aliphatic segments in thepolycarbonate chain. For example, the following aliphatic soft segmentsthat may be excluded from the cross-linkable polycarbonates of theinvention include aliphatic polyesters, aliphatic polyethers, aliphaticpolythioeithers, aliphatic polyacetals, aliphatic polycarbonates, C—Clinked polymers and polysiloxanes. The soft segments of aliphaticpolyesters, aliphatic polyethers, aliphatic polythioeithers, aliphaticpolyacetals, aliphatic polycarbonates may be characterized as havingNumber Average MWs (Mns) of greater than 600.

In certain embodiments, the cross-linkable polycarbonates of theinvention do not include units derived from aromatic di-, tri-, ortetrahydroxyketones.

In certain embodiments, the cross-linkable polycarbonates of theinvention do not include units derived from dihydroxybenzophenonemonomers, trihydroxybenzophenone monomers, tetrahydroxybenzophenonemonomers, or other multiple-hydroxybenzophenone monomers. For example,the following monomer units may be excluded from use in thecross-linkable and cross-linked polycarbonates of the invention:4,4′-dihydroxybenzophenone, 2,4-dihydroxybenzophenone, and4-(α,α-bis(4-hydroxyphenyl)ethyl-benzophenone.

(i) Homopolycarbonates/Copolycarbonates

The cross-linkable polycarbonate of the invention may be ahomopolycarbonate or a copolycarbonate, provided that the cross-linkablepolycarbonate comprises endcap groups derived from amonohydroxybenzophenone. The term “polycarbonate” and “polycarbonateresin” mean compositions having repeating structural carbonate units ofthe formula (1):

wherein R¹⁰⁰ may comprise any suitable organic group, such as analiphatic, alicyclic, or aromatic group, or any combination thereof. Incertain embodiments, R¹⁰⁰ in the carbonate units of formula (1) may be aC₆-C₃₆ aromatic group wherein at least one moiety is aromatic.

In certain embodiments, each R¹⁰⁰ may be an aromatic organic group, forexample, a group of formula (2):

-A¹-Y¹-A²-  (2)

wherein each of the A¹ and A² is a monocyclic divalent aryl group and Y¹is a bridging group having one or two atoms that separate A¹ and A². Forexample, one atom may separate A¹ from A², with illustrative examples ofthese groups including —O—, —S—, —S(O)—, —S(O)₂—, —C(O)—, methylene,cyclohexyl-methylene, 2-[2.2.1]-bicycloheptylidene, ethylidene,isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecyclidene,cyclododecylidene, and adamantylidene. The bridging group of Y¹ may be ahydrocarbon group or a saturated hydrocarbon group such as methylene,cyclohexylidene, or isopropylidene.

Each R¹⁰⁰ may be derived from a dihydroxy monomer unit. The dihydroxymonomer unit may have formula (3):

HO-A¹-Y¹-A²-OH  (3)

wherein each of the A¹ and A² is a monocyclic divalent aryl group and Y¹is a bridging group having one or two atoms that separate A¹ and A². Forexample, one atom may separate A¹ from A², with illustrative examples ofthese groups including —O—, —S—, —S(O)—, —S(O)₂—, —C(O)—, methylene,cyclohexyl-methylene, 2-[2.2.1]-bicycloheptylidene, ethylidene,isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecyclidene,cyclododecylidene, and adamantylidene. The bridging group of Y¹ may be ahydrocarbon group or a saturated hydrocarbon group such as methylene,cyclohexylidene, or isopropylidene.

The dihydroxy monomer unit of formula (3) may include bisphenolcompounds of the general formula (4):

wherein X^(a) may be a bridging group connecting the twohydroxy-substituted aromatic groups, where the bridging group and thehydroxy substituent of each C₆ arylene group are disposed ortho, meta,or para (specifically para) to each other on the C₆ arylene group. Forexample, the bridging group X^(a) may be single bond, —O—, —S—, —C(O)—,or a C₁-C₁₈ organic group. The C₁-C₁₈ organic bridging group may becyclic or acyclic, aromatic or non-aromatic, and can further compriseheteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, orphosphorous. The C₁-C₁₈ organic group can be disposed such that the C₆arylene groups connected thereto are each connected to a commonalkylidene carbon or to different carbons of the C₁-C₁₈ organic bridginggroup. R^(a) and R^(b) may each represent a halogen, C₁-C₁₂ alkyl groupor combination thereof. For example, R^(a) and R^(b) may each be a C₁-C₃alkyl group, specifically methyl, disposed meta to the hydroxy group oneach arylene group. The designation (e) is 0 or 1. The numbers p and qare each independently integers of 0 to 4. It will be understood thatR^(a) is hydrogen when p is 0, and likewise R^(b) is hydrogen when q is0.

In certain embodiments, X^(a) may be substituted or unsubstituted C₃-C₁₈cycloalkylidene, a C₁-C₂₅ alkylidene of formula —C(R^(c))(R^(d))—wherein R^(c) and R^(d) are each independently hydrogen, C₁-C₁₂ alkyl,C₁-C₁₂ cycloalkyl, C₇-C₁₂ arylalkyl, C₁-C₁₂ heteroalkyl, or cyclicC₇-C₁₂ heteroarylalkyl, or a group of the formula —C(═R^(e))— whereinR^(e) is a divalent C₁-C₁₂ hydrocarbon group. This may includemethylene, cyclohexylmethylene, ethylidene, neopentylidene, andisopropylidene, as well as 2-[2.2.1]-bicycloheptylidene,cyclohexylidene, cyclopentylidene, cyclododecylidene, andadamantylidene. A specific example wherein X^(a) is a substitutedcycloalkylidene is the cyclohexylidene-bridged, alkyl-substitutedbisphenol of formula (5):

wherein R^(a′) and R^(b′) are each independently C₁-C₁₂ alkyl, R^(g) isC₁-C₁₂ alkyl or halogen, r and s are each independently 1 to 4, and t is0 to 10. R^(a′) and R^(b′) may be disposed meta to the cyclohexylidenebridging group. The substituents R^(a′), R^(b′) and R^(g) may, whencomprising an appropriate number of carbon atoms, be straight chain,cyclic, bicyclic, branched, saturated, or unsaturated. For example,R^(a′), R^(b′) and R^(g) may be each independently C₁-C₄ alkyl, r and sare each 1, and t is 0 to 5. In another example, R^(a′), R^(b′) andR^(g) may each be methyl, r and s are each 1, and t is 0 or 3. Thecyclohexylidene-bridged bisphenol can be the reaction product of twomoles of o-cresol with one mole of cyclohexanone. In another example,the cyclohexylidene-bridged bisphenol may be the reaction product of twomoles of a cresol with one mole of a hydrogenated isophorone (e.g.,1,1,3-trimethyl-3-cyclohexane-5-one). Such cyclohexane-containingbisphenols, for example the reaction product of two moles of a phenolwith one mole of a hydrogenated isophorone, are useful for makingpolycarbonate polymers with high glass transition temperatures and highheat distortion temperatures. Cyclohexyl bisphenol-containingpolycarbonates, or a combination comprising at least one of theforegoing with other bisphenol polycarbonates, are supplied by Bayer Co.under the APEC® trade name.

X^(a) may be a C₁-C₁₈ alkylene group, a C₃-C₁₈ cycloalkylene group, afused C₆-C₁₈ cycloalkylene group, or a group of the formula —B¹—W—B²—wherein B¹ and B² are the same or different C₁-C₆ alkylene group and Wis a C₃-C₁₂ cycloalkylidene group or a C₆-C₁₆ arylene group.

In another example, X^(a) may be a substituted C₃-C₁₈ cycloalkylidene ofthe formula (6):

wherein R^(r), R^(p), R^(q) and R^(t) are each independently hydrogen,halogen, oxygen, or C₁-C₁₂ organic groups; I is a direct bond, a carbon,or a divalent oxygen, sulfur, or —N(Z)— where Z is hydrogen, halogen,hydroxy, C₁-C₁₂ alkyl, C₁-C₁₂ alkoxy, C₆-C₁₂ aryl, or C₁-C₁₂ acyl; h is0 to 2, j is 1 or 2, i is an integer of 0 or 1, and k is an integer of 0to 3, with the proviso that at least two of R^(r), R^(p), R^(q) andR^(t) taken together are a fused cycloaliphatic, aromatic, orheteroaromatic ring. It will be understood that where the fused ring isaromatic, the ring as shown in formula (6) will have an unsaturatedcarbon-carbon linkage where the ring is fused. When i is 0, h is 0, andk is 1, the ring as shown in formula (6) contains 4 carbon atoms; when iis 0, h is 0, and k is 2, the ring as shown contains 5 carbon atoms, andwhen i is 0, h is 0, and k is 3, the ring contains 6 carbon atoms. Inone example, two adjacent groups (e.g., R^(q) and R^(t) taken together)form an aromatic group, and in another embodiment, R^(q) and R^(t) takentogether form one aromatic group and R^(r) and R^(p) taken together forma second aromatic group. When R^(q) and R^(t) taken together form anaromatic group, R^(p) can be a double-bonded oxygen atom, i.e., aketone.

Other useful dihydroxy monomer units include aromatic dihydroxycompounds of formula (7):

wherein each R^(h) is independently a halogen atom, a C₁-C₁₀ hydrocarbylsuch as a C₁-C₁₀ alkyl group, a halogen substituted C₁-C₁₀ hydrocarbylsuch as a halogen-substituted C₁-C₁₀ alkyl group, and n is 0 to 4. Thehalogen, when present, is usually bromine.

Bisphenol-type dihydroxy aromatic compounds may include the following:4,4′-dihydroxybiphenyl, 1,6-dihydroxynaphthalene,2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane,bis(4-hydroxyphenyl)diphenylmethane,bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane,1,1-bis(4-hydroxyphenyl)-1-phenylethane,2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane,bis(4-hydroxyphenyl)phenylmethane,2,2-bis(4-hydroxy-3-bromophenyl)propane,1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane,1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane,1,1-bis(4-hydroxyphenyl)isobutene,1,1-bis(4-hydroxyphenyl)cyclododecane,trans-2,3-bis(4-hydroxyphenyl)-2-butene,2,2-bis(4-hydroxyphenyl)adamantane, (alpha,alpha′-bis(4-hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile,2,2-bis(3-methyl-4-hydroxyphenyl)propane,2,2-bis(3-ethyl-4-hydroxyphenyl)propane,2,2-bis(3-n-propyl-4-hydroxyphenyl)propane,2,2-bis(3-isopropyl-4-hydroxyphenyl)propane,2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane,2,2-bis(3-t-butyl-4-hydroxyphenyl)propane,2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane,2,2-bis(3-allyl-4-hydroxyphenyl)propane,2,2-bis(3-methoxy-4-hydroxyphenyl)propane,2,2-bis(4-hydroxyphenyl)hexafluoropropane,1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene,1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene,1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene,4,4′-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone,1,6-bis(4-hydroxyphenyl)-1,6-hexanedione, ethylene glycolbis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether,bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide,bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxyphenyl)fluorene,2,7-dihydroxypyrene,6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane (“spirobiindanebisphenol”), 3,3-bis(4-hydroxyphenyl)phthalide,2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene,2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine,3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and2,7-dihydroxycarbazole, and the like, as well as combinations comprisingat least one of the foregoing dihydroxy aromatic compounds.

Examples of the types of bisphenol compounds represented by formula (3)may include 1,1-bis(4-hydroxyphenyl)methane,1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane (alsoreferred to as “bisphenol-A” or “BPA”), 2,2-bis(4-hydroxyphenyl)butane,2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane,1,1-bis(4-hydroxyphenyl)n-butane,2,2-bis(4-hydroxy-1-methylphenyl)propane,1,1-bis(4-hydroxy-t-butylphenyl)propane,3,3-bis(4-hydroxyphenyl)phthalimidine,2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (“PPPBP”),9,9-bis(4-hydroxyphenyl)fluorene, and1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (“DMBPC”). Combinationscomprising at least one of the foregoing dihydroxy aromatic compoundscan also be used.

The dihydroxy compounds of formula (3) may be the following formula (8)for high heat applications:

wherein R¹³ and R¹⁵ are each independently a halogen or a C₁-C₆ alkylgroup, R¹⁴ is a C₁-C₆ alkyl, phenyl, or phenyl substituted with up tofive halogens or C₁-C₆ alkyl groups, and c is 0 to 4. In a specificembodiment, R¹⁴ is a C₁-C₆ alkyl or phenyl group. In still anotherembodiment, R¹⁴ is a methyl or phenyl group. In another specificembodiment, each c is 0.

The dihydroxy compounds of formula (3) may be the following formula (9)for high heat applications:

(also known as 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one(PPPBP)).

Alternatively, the dihydroxy compounds of formula (3) may be thefollowing formula (10) for high heat applications:

(also known as 4,4′-(1-phenylethane-1,1-diyl)diphenol (bisphenol-AP) or1,1-bis(4-hydroxyphenyl)-1-phenyl-ethane).

Alternatively, the dihydroxy compounds of formula (3) may be thefollowing formula (11) for high heat applications:

(bisphenol TMC) or 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane).

Other dihydroxy compounds that might impart high Tgs to thepolycarbonate as a copolycarbonate are dihydroxy compounds havingadamantane units, as described in U.S. Pat. No. 7,112,644 and U.S. Pat.No. 3,516,968, which are fully incorporated herein by reference. Acompound having adamantane units may have repetitive units of thefollowing formula (12) for high heat applications:

wherein R₁ represents a halogen atom, an alkyl group having 1 to 6carbon atoms, an alkoxy group having 1 to 6 carbon atoms, an aryl grouphaving 6 to 12 carbon atoms, an aryl-substituted alkenyl group having 7to 13 carbon atoms, or a fluoroalkyl group having 1 to 6 carbon atoms;R₂ represents a halogen atom, an alkyl group having 1 to 12 carbonatoms, an alkoxy group having 1 to 12 carbon atoms, an aryl group having6 to 12 carbon atoms, an aryl-substituted alkenyl group having 7 to 13carbon atoms, or a fluoroalkyl group having 1 to 12 carbon atoms; mrepresents an integer of 0 to 4; and n represents an integer of 0 to 14.

Other dihydroxy compounds that might impart high Tgs to thepolycarbonate as a copolycarbonate are dihydroxy compounds havingfluorene-units, as described in U.S. Pat. No. 7,244,804. One suchfluorene-unit containing dihydroxy compound is represented by thefollowing formula (13) for high heat applications:

wherein R₁ to R₄ are each independently a hydrogen atom, a hydrocarbongroup with 1 to 9 carbon atoms which may contain an aromatic group, or ahalogen atom.

(ii) Isosorbide-Containing Polycarbonates

The cross-linkable polycarbonate of the invention may be a copolymercomprising repeating units as described above and other types of polymerunits such isosorbide containing polycarbonate units. In certainembodiments, R¹⁰⁰ of formula (1) may be derived from a monomer unitderived from isosorbide. The monomer unit derived from isosorbide may bean isorbide-bisphenol unit of formula (14):

wherein R₁ is an isosorbide unit and R₂-R₉ are each independently ahydrogen, a halogen, a C₁-C₆ alkyl, a methoxy, an ethoxy, or an alkylester.

The R₁ isosorbide unit may be represented by formula (15):

The isosorbide unit may be derived from an isosorbide, a mixture ofisosorbide, a mixture of isomers of isosorbide, and/or from individualisomers of isosorbide. The stereochemistry for the isosorbide-basedcarbonate units of formula (15) is not particularly limited.

The R₁ isosorbide unit may be derived from an isosorbide of generalformula (16):

and can be a single diol isomer or mixture of diol isomers. Thestereochemistry for the isosorbide of formula (16) is also notparticularly limited. These diols may be prepared by the dehydration ofthe corresponding hexitols. Hexitols are produced commercially from thecorresponding sugars (aldohexose). Aliphatic diols of formula (16)include 1,4:3,6-dianhydro-D glucitol, of formula (17);1,4:3,6-dianhydro-D mannitol, of formula (18); and 1,4:3,6-dianhydro-Liditol, of formula (19), and any combination thereof. Isosorbides areavailable commercially from various chemical suppliers includingCargill, Roquette, and Shanxi.

The diol of formula (17) may be desirable because it is a rigid,chemically and thermally stable aliphatic diol that may be used toproduce higher Tg copolymers. The isosorbide-bisphenol may have a pKa ofbetween 8 and 11.

(iii) Polyester-Polycarbonates

The cross-linkable polycarbonate of the invention may be a copolymercomprising repeating units as described above, and other types ofpolymer units such as polyester units. A specific type of copolymer maybe a polyester-polycarbonate. The polyester-polycarbonate may compriserepeating ester units of formula (20a):

wherein O-D-O of formula (20a) is a divalent group derived from adihydroxy compound, and D may be, for example, one or more alkylcontaining C₆-C₂₀ aromatic group(s), or one or more C₆-C₂₀ aromaticgroup(s), a C₂-C₁₀ alkylene group, a C₆-C₂₀ alicyclic group, a C₆-C₂₀aromatic group or a polyoxyalkylene group in which the alkylene groupscontain 2 to about 6 carbon atoms, specifically 2, 3, or 4 carbon atoms.D may be a C₂-C₃₀ alkylene group having a straight chain, branchedchain, or cyclic (including polycyclic) structure. O-D-O may be derivedfrom an aromatic dihydroxy compound of formula (3), as described above.O-D-O may be derived from an aromatic dihydroxy compound of formula (4),as described above. O-D-O may be derived from an aromatic dihydroxycompound of Formula (14), as described above.

The molar ratio of ester units to carbonate units in thepolyester-polycarbonates may vary broadly, for example 1:99 to 99:1,specifically 10:90 to 90:10, more specifically 25:75 to 75:25,optionally expanded depending on the desired properties of the finalcomposition.

T of formula (20a) may be a divalent group derived from a dicarboxylicacid, and may be, for example, a C₂-C₁₀ alkylene group, a C₆-C₂₀alicyclic group, a C₆-C₂₀ alkyl aromatic group, a C₆-C₂₀ aromatic group,or a C₆-C₃₆ divalent organic group derived from a dihydroxy compound orchemical equivalent thereof. T may be an aliphatic group, wherein themolar ratio of carbonate units to ester units of formula (20a) in thepoly(aliphatic ester)-polycarbonate copolymer is from 99:1 to 60:40; and0.01 to 10 weight percent, based on the total weight of the polymercomponent, of a polymeric containing compound. T may be derived from aC₆-C₂₀ linear aliphatic alpha-omega (α-ω) dicarboxylic ester.

Diacids from which the T group in the ester unit of formula (20a) isderived include aliphatic dicarboxylic acids having from 6 to about 36carbon atoms, optionally from 6 to 20 carbon atoms. The C₆-C₂₀ linearaliphatic alpha-omega (α-ω) dicarboxylic acids may be adipic acid,sebacic acid, 3,3-dimethyl adipic acid, 3,3,6-trimethyl sebacic acid,3,3,5,5-tetramethyl sebacic acid, azelaic acid, dodecanedioic acid,dimer acids, cyclohexane dicarboxylic acids, dimethyl cyclohexanedicarboxylic acid, norbornane dicarboxylic acids, adamantanedicarboxylic acids, cyclohexene dicarboxylic acids, or C₁₄, C₁₈ and C₂₀diacids.

The ester units of the polyester-polycarbonates of formula (20a) can befurther described by formula (20b), wherein T is (CH₂)_(m), where m is 4to 40.

Saturated aliphatic alpha-omega dicarboxylic acids may be adipic acid,sebacic or dodecanedioic acid. Sebacic acid is a dicarboxylic acidhaving the following formula (21):

Sebacic acid has a molecular mass of 202.25 Daltons, a density of 1.209g/cm³ (25° C.), and a melting point of 294.4° C. at 100 mmHg. Sebacicacid is extracted from castor bean oil found in naturally occurringcastor beans.

Other examples of aromatic dicarboxylic acids that may be used toprepare the polyester units include isophthalic or terephthalic acid,1,2-di(p-carboxyphenyl)ethane, 4,4′-dicarboxydiphenyl ether,4,4′-bisbenzoic acid, and combinations comprising at least one of theforegoing acids. Acids containing fused rings can also be present, suchas in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specificdicarboxylic acids may be terephthalic acid, isophthalic acid,naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, orcombinations thereof. A specific dicarboxylic acid comprises acombination of isophthalic acid and terephthalic acid wherein the weightratio of isophthalic acid to terephthalic acid is about 91:9 to about2:98.

D of the repeating units of formula (20a) may also be a C₂-C₆ alkylenegroup and T may be p-phenylene, m-phenylene, naphthalene, a divalentcycloaliphatic group, or a combination thereof. This class of polyesterincludes the poly(alkylene terephthalates).

Mixtures of the diacids can also be employed. It should be noted thatalthough referred to as diacids, any ester precursor could be employedsuch as acid halides, specifically acid chlorides, and diaromatic estersof the diacid such as diphenyl, for example the diphenyl ester ofsebacic acid. With reference to the diacid carbon atom number earliermentioned, this does not include any carbon atoms which may be includedin the ester precursor portion, for example diphenyl. It may bedesirable that at least four, five or six carbon bonds separate the acidgroups. This may reduce the formation of undesirable and unwanted cyclicspecies.

The polyester unit of a polyester-polycarbonate may be derived from thereaction of a combination of isophthalic and terephthalic diacids (orderivatives thereof) with resorcinol. In another embodiment, thepolyester unit of a polyester-polycarbonate may be derived from thereaction of a combination of isophthalic acid and terephthalic acid withbisphenol-A. In an embodiment, the polycarbonate units may be derivedfrom bisphenol-A. In another specific embodiment, the polycarbonateunits may be derived from resorcinol and bisphenol-A in a molar ratio ofresorcinol carbonate units to bisphenol-A carbonate units of 1:99 to99:1.

Useful polyesters may include aromatic polyesters, poly(alkylene esters)including poly(alkylene arylates), and poly(cycloalkylene diesters).Aromatic polyesters may have a polyester structure according to formula(20a), wherein D and T are each aromatic groups as describedhereinabove. Useful aromatic polyesters may include, for example,poly(isophthalate-terephthalate-resorcinol) esters,poly(isophthalate-terephthalate-bisphenol-A) esters,poly[(isophthalate-terephthalate-resorcinol)ester-co-(isophthalate-terephthalate-bisphenol-A)]ester, or acombination comprising at least one of these.

The polyester-polycarbonate may have a biocontent according toASTM-D-6866 of at least 2 weight %, at least 3 weight %, at least 4weight %, at least 5 weight %, at least 6 weight %, at least 7 weight %,at least 8 weight %, at least 9 weight %, at least 10 weight %, at least11 weight %, at least 12 weight %, at least 13 weight %, at least 14weight %, at least 15 weight %, at least 16 weight %, at least 17 weight%, at least 18 weight %, at least 19 weight %, at least 20 weight %, atleast 25 weight %, at least 30 weight %, at least 35 weight %, at least40 weight %, at least 45 weight %, at least 50 weight %, at least 55weight %, at least 60 weight %, or at least 65 weight % of thecomposition derived therefrom. The polymer, or any composition derivedtherefrom, may have at least 5.0 weight percent of sebacic acid content.

(iv) Polycarbonate Polysiloxane Copolymers

The cross-linkable polycarbonate of the invention may be a copolymercomprising other types of polymer units such as polysiloxane units. Thepolycarbonate structural unit of the polycarbonate-polysiloxanecopolymer may comprise carbonate units derived from other monomers, suchas the monomers of formula (3), formula (4), and/or formula (14), asdescribed above.

The polysiloxane structural unit may be derived from siloxane-containingdihydroxy compounds (also referred to herein as “hydroxyaryl endcappedpolysiloxanes”) that contain diorganosiloxane units blocks of formula(22):

wherein each occurrence of R is the same or different, and is a C₁-C₁₃monovalent organic group. For example, R can be a C₁-C₁₃ alkyl group,C₁-C₁₃ alkoxy group, C₂-C₁₃ alkenyl group, C₂-C₁₃ alkenyloxy group,C₃-C₆ cycloalkyl group, C₃-C₆ cycloalkoxy group, C₆-C₁₄ aryl group,C₆-C₁₀ aryloxy group, C₇-C₁₃ aralkyl group, C₇-C₁₃ aralkoxy group,C₇-C₁₃ alkylaryl group, or C₇-C₁₃ alkylaryloxy group. The foregoinggroups can be fully or partially halogenated with fluorine, chlorine,bromine, or iodine, or a combination thereof. In an embodiment, where atransparent polycarbonate is desired, R does not contain any halogen.Combinations of the foregoing R groups can be used in the samepolycarbonate.

The value of E in formula (22) can vary widely depending on the type andrelative amount of each of the different units in the polycarbonate, thedesired properties of the polycarbonate, and like considerations.Generally, E can have an average value of about 2 to about 1,000,specifically about 2 to about 500, more specifically about 2 to about100. In an embodiment, E has an average value of about 4 to about 90,specifically about 5 to about 80, and more specifically about 10 toabout 70. Where E is of a lower value, e.g., less than about 40, it canbe desirable to use a relatively larger amount of the units containingthe polysiloxane. Conversely, where E is of a higher value, e.g.,greater than about 40, it can be desirable to use a relatively loweramount of the units containing the polysiloxane.

In one embodiment, the polysiloxane blocks are provided by repeatingstructural units of formula (23):

wherein E is as defined above; each R is the same or different, and isas defined above; and each Ar is the same or different, and Ar is one ormore C₆-C₃₀ aromatic group(s), or one or more alkyl containing C₆-C₃₀aromatic group(s), wherein the bonds are directly connected to anaromatic moiety. —O—Ar—O— groups in formula (23) can be derived from,for example, a C₆-C₃₀ dihydroxyaromatic compound. Combinationscomprising at least one of the foregoing dihydroxyaromatic compounds canalso be used. Exemplary dihydroxyaromatic compounds are1,1-bis(4-hydroxyphenyl) methane, 1,1-bis(4-hydroxyphenyl)ethane,2,2-bis(4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)butane,2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane,1,1-bis(4-hydroxyphenyl)n-butane,2,2-bis(4-hydroxy-1-methylphenyl)propane,1,1-bis(4-hydroxyphenyl)cyclohexane, bis(4-hydroxyphenyl sulfide),1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, and1,1-bis(4-hydroxy-t-butylphenyl)propane, or a combination comprising atleast one of the foregoing dihydroxy compounds.

Polycarbonates comprising such units can be derived from thecorresponding dihydroxy compound of formula (24):

wherein Ar and E are as described above. Compounds of formula (24) canbe obtained by the reaction of a dihydroxyaromatic compound with, forexample, an alpha, omega-bis-acetoxy-polydiorganosiloxane oligomer underphase transfer conditions. Compounds of formula (24) can also beobtained from the condensation product of a dihydroxyaromatic compound,with, for example, an alpha, omega bis-chloro-polydimethylsiloxaneoligomer in the presence of an acid scavenger.

In a specific embodiment, Ar from formula (24) is derived fromresorcinol, and the polydiorganosiloxane repeating units are a dihydroxyaromatic compound of formula (25):

or, wherein Ar is derived from bisphenol-A, and the polydiorganosiloxanerepeating units are a dihydroxy aromatic compound of formula (26):

wherein E has an average value of between 20 and 75.

In another embodiment, polydiorganosiloxane blocks comprise units offormula (27):

wherein R and E are as described above, and each R₆ is independently adivalent C₁-C₃₀ organic group such as a C₁-C₃₀ alkyl, C₁-C₃₀ aryl, orC₁-C₃₀ alkylaryl. The polysiloxane blocks corresponding to formula (27)are derived from the corresponding dihydroxy compound of formula (28):

wherein R and E and R₆ are as described for formula (27).

In a specific embodiment, the polydiorganosiloxane blocks are derivedfrom a polysiloxane monomer having the structure (29):

wherein E is an average value of between 20 and 75.

In another specific embodiment, the polydiorganosiloxane blocks arederived from a polysiloxane monomer having the structure (30):

wherein E is an average value of between 20 and 75.

In a specific embodiment, the polydiorganosiloxane blocks are providedby repeating structural units of formula (31):

wherein R and E are as defined above. R₇ in formula (31) is a divalentC₂-C₈ aliphatic group. Each M in formula (31) can be the same ordifferent, and is a halogen, cyano, nitro, C₁-C₈ alkylthio, C₁-C₈ alkyl,C₁-C₈ alkoxy, C₂-C₈ alkenyl, C₂-C₈ alkenyloxy group, C₃-C₈ cycloalkyl,C₃-C₈ cycloalkoxy, C₆-C₁₀ aryl, C₆-C₁₀ aryloxy, C₇-C₁₂ aralkyl, C₇-C₁₂aralkoxy, C₇-C₁₂ alkylaryl, or C₇-C₁₂ alkylaryloxy, wherein each n isindependently 0, 1, 2, 3, or 4.

In one embodiment, M of formula (31) is bromo or chloro, an alkyl groupsuch as methyl, ethyl, or propyl, an alkoxy group such as methoxy,ethoxy, or propoxy, or an aryl group such as phenyl, chlorophenyl, ortolyl; n is 0 to 4; R₇ is a dimethylene, trimethylene or tetramethylenegroup; and R is a C₁-C₈ alkyl, haloalkyl such as trifluoropropyl,cyanoalkyl, or aryl such as phenyl, chlorophenyl or tolyl. In anotherembodiment, R is methyl, or a combination of methyl and trifluoropropyl,or a combination of methyl and phenyl. In still another embodiment, M ismethoxy, n is one, R₇ is a divalent C₁-C₃ aliphatic group, and R ismethyl.

Polysiloxane-polycarbonates comprising units of formula (31) can bederived from the corresponding dihydroxy polydiorganosiloxane (32):

wherein each of R, E, M, R₇, and n are as described above. Suchdihydroxy polysiloxanes can be made by affecting a platinum-catalyzedaddition between a siloxane hydride of formula (33):

wherein R and E are as previously defined, and an aliphaticallyunsaturated monohydric phenol. Exemplary aliphatically unsaturatedmonohydric phenols include, for example, eugenol, 2-allylphenol,4-allyl-2-methylphenol, 4-allyl-2-phenylphenol, 4-allyl-2-bromophenol,4-allyl-2-t-butoxyphenol, 4-phenyl-2-phenylphenol,2-methyl-4-propylphenol, 2-allyl-4,6-dimethylphenol,2-allyl-4-bromo-6-methylphenol, 2-allyl-6-methoxy-4-methylphenol,4-allylphenol, and 2-allyl-4,6-dimethylphenol. Combinations comprisingat least one of the foregoing can also be used.

In certain embodiments, the cross-linkable polycarbonates of theinvention do not comprise polysiloxane units.

(v) Monohydroxybenzophenone End Capping Agents

Endcapping agents (also referred to as a chain-stopper) are used tolimit molecular weight growth rate, and so control molecular weight. Alltypes of polycarbonate end groups are contemplated as being useful inthe cross-linkable polycarbonates of the invention, provided that suchend groups do not significantly adversely affect desired properties ofthe compositions, and provided that the cross-linkable polycarbonatescomprise at least some endcap group content derived from one or moremonohydroxybenzophenones

The monohydroxybenzophenone endcaps of the cross-linkable polycarbonatesprovide a reactive functional group for cross-linking thepolycarbonates. For example, treatment of a cross-linkable polycarbonateof the invention with a suitable dose of ultra-violet radiation, asfurther described herein, may initiate cross-linking reaction betweenthe monohydroxybenzophenone carbonyl carbon and a carbon atom of anotherfunctional group (e.g., a methylene carbon atom, such as in bisphenol-A)in the same polymer or another polymer in the composition.

Suitable monohydroxybenzophenone chain-stoppers include, but are notlimited to, 2-hydroxybenzophenone, 3-hydroxybenzophenone,4-hydroxybenzophenone, 4-hydroxybenzoylbenzophenone,2-hydroxy-4-methoxybenzophenone,2-hydroxy-4-methoxy-2′-carboxybenzophenone,2-hydroxy-4-octoxybenzophenone, 2-hydroxy-4-stearoxybenzophenone,4-dodecyloxy-2-hydroxybenzophenone,2-hydroxy-4-methoxy-5-sulfobenzophenone trihydrate, and2-hydroxy-4-methoxybenzophenone-5-sulfonic acid. In one preferredembodiment, the monohydroxybenzophenone chain stopper is a2-hydroxybenzophenone, 3-hydroxybenzophenone, or 4-hydroxybenzophenone,each of which may be further substituted with one or more additionalsubstituents, provided the monohydroxybenzophenone still functions as achain-stopper. In another preferred embodiment, themonohydroxybenzophenone is 4-hydroxybenzophenone.

(vi) Other End Capping Agents

Other end capping agents can be incorporated into the cross-linkablepolycarbonates. Exemplary chain-stoppers include certain monophenoliccompounds (i.e., phenyl compounds having a single free hydroxy group),monocarboxylic acid chlorides, monocarboxylic acids, and/ormonochloroformates. Phenolic chain-stoppers are exemplified by phenoland C₁-C₂₂ alkyl-substituted phenols such as p-cumyl-phenol, resorcinolmonobenzoate, and p-tertiary-butylphenol, cresol, and monoethers ofdiphenols, such as p-methoxyphenol. Exemplary chain-stoppers alsoinclude cyanophenols, such as for example, 4-cyanophenol, 3-cyanophenol,2-cyanophenol, and polycyanophenols. Alkyl-substituted phenols withbranched chain alkyl substituents having 8 to 9 carbon atoms can bespecifically be used.

Endgroups can be derived from the carbonyl source (i.e., the diarylcarbonate), from selection of monomer ratios, incomplete polymerization,chain scission, and the like, as well as any added endcapping groups,and can include derivatizable functional groups such as hydroxy groups,carboxylic acid groups, or the like. In an embodiment, the endgroup of apolycarbonate can comprise a structural unit derived from a diarylcarbonate, where the structural unit can be an endgroup. In a furtherembodiment, the endgroup is derived from an activated carbonate. Suchendgroups can derive from the transesterification reaction of the alkylester of an appropriately substituted activated carbonate, with ahydroxy group at the end of a polycarbonate polymer chain, underconditions in which the hydroxy group reacts with the ester carbonylfrom the activated carbonate, instead of with the carbonate carbonyl ofthe activated carbonate. In this way, structural units derived fromester containing compounds or substructures derived from the activatedcarbonate and present in the melt polymerization reaction can form esterendgroups. In an embodiment, the ester endgroup derived from a salicylicester can be a residue of bis(methyl salicyl) carbonate (BMSC) or othersubstituted or unsubstituted bis(alkyl salicyl) carbonate such asbis(ethyl salicyl) carbonate, bis(propyl salicyl) carbonate, bis(phenylsalicyl) carbonate, bis(benzyl salicyl) carbonate, or the like. In aspecific embodiment, where BMSC is used as the activated carbonylsource, the endgroup is derived from and is a residue of BMSC, and is anester endgroup derived from a salicylic acid ester, having the structureof formula (34):

(vii) Branching Groups

The cross-linkable polycarbonates of the invention may include branchinggroups, provided that such branching does not significantly adverselyaffect desired properties of the polycarbonate. Branched polycarbonateblocks can be prepared by adding a branching agent duringpolymerization. These branching agents include polyfunctional organiccompounds containing at least three functional groups selected fromhydroxyl, carboxyl, carboxylic anhydride, haloformyl, and mixtures ofthe foregoing functional groups. Specific examples include trimelliticacid, trimellitic anhydride, trimellitic trichloride, tris-p-hydroxyphenyl ethane, isatin-bis-phenol, tris-phenol TC(1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA(4(4(1,1-bis(p-hydroxyphenyl)-ethyl)alpha, alpha-dimethylbenzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, andbenzophenone tetracarboxylic acid. The branching agents can be added ata level of about 0.05 to about 6.0 wt %. Mixtures comprising linearpolycarbonates and branched polycarbonates can be used.

(viii) Methods of Making Polycarbonates

The cross-linkable polycarbonate of the invention may be manufactured byprocesses such as interfacial polymerization and melt polymerization.High Tg copolycarbonates are generally manufactured using interfacialpolymerization. Although the reaction conditions for interfacialpolymerization can vary, an exemplary process generally involvesdissolving or dispersing one or more dihydric phenol reactants, such asbisphenol-A, in aqueous caustic soda or potash, adding the resultingmixture to a water-immiscible solvent medium, and contacting thereactants with a carbonate precursor in the presence of a catalyst suchas, for example, a tertiary amine or a phase transfer catalyst, undercontrolled pH conditions, e.g., 8 to 11. The most commonly used waterimmiscible solvents include methylene chloride, 1,2-dichloroethane,chlorobenzene, toluene, and the like.

Exemplary carbonate precursors may include, for example, a carbonylhalide such as carbonyl dibromide or carbonyl dichloride (also known asphosgene), or a haloformate such as a bishaloformate of a dihydricphenol (e.g., the bischloroformate of bisphenol-A, hydroquinone, or thelike) or a glycol (e.g., the bishaloformate of ethylene glycol,neopentyl glycol, polyethylene glycol, or the like). Combinationscomprising at least one of the foregoing types of carbonate precursorscan also be used. In certain embodiments, the carbonate precursor isphosgene, a triphosgene, diacyl halide, dihaloformate, dicyanate,diester, diepoxy, diarylcarbonate, dianhydride, dicarboxylic acid,diacid chloride, or any combination thereof. An interfacialpolymerization reaction to form carbonate linkages may use phosgene as acarbonate precursor, and is referred to as a phosgenation reaction.

Among tertiary amines that can be used are aliphatic tertiary aminessuch as triethylamine, tributylamine, cycloaliphatic amines such asN,N-diethyl-cyclohexylamine and aromatic tertiary amines such asN,N-dimethylaniline.

Among the phase transfer catalysts that can be used are catalysts of theformula (R³⁰)₄Q⁺X, wherein each R³⁰ is the same or different, and is aC₁-C₁₀ alkyl group; Q is a nitrogen or phosphorus atom; and X is ahalogen atom, C₁-C₈ alkoxy group, or C₆-C₁₈ aryloxy group. Exemplaryphase transfer catalysts include, for example, [CH₃(CH₂)₃]₄NX,[CH₃(CH₂)₃]₄PX, [CH₃(CH₂)₅]₄NX, [CH₃(CH₂)₆]₄NX, [CH₃(CH₂)₄]₄NX,CH₃[CH₃(CH₂)₃]₃NX, and CH₃[CH₃(CH₂)₂]₃NX, wherein X is Cl⁻, Br⁻, a C₁-C₈alkoxy group or a C₆-C₁₈ aryloxy group. An effective amount of a phasetransfer catalyst can be 0.1 to 10 wt % based on the weight of bisphenolin the phosgenation mixture. For example, an effective amount of phasetransfer catalyst can be 0.5 to 2 wt % based on the weight of bisphenolin the phosgenation mixture.

The polycarbonate may be prepared by a melt polymerization process.Generally, in the melt polymerization process, polycarbonates areprepared by co-reacting, in a molten state, the dihydroxy reactant(s)(e.g., aliphatic diol and/or aliphatic diacid, and any additionaldihydroxy compound) and a diaryl carbonate ester, such as diphenylcarbonate, or more specifically in an embodiment, an activated carbonatesuch as bis(methyl salicyl) carbonate, in the presence of atransesterification catalyst. The reaction may be carried out in typicalpolymerization equipment, such as one or more continuously stirredreactors (CSTR's), plug flow reactors, wire wetting fall polymerizers,free fall polymerizers, wiped film polymerizers, BANBURY® mixers, singleor twin screw extruders, or combinations of the foregoing. Volatilemonohydric phenol is removed from the molten reactants by distillationand the polymer is isolated as a molten residue. A specifically usefulmelt process for making polycarbonates uses a diaryl carbonate esterhaving electron-withdrawing substituents on the aryls. Examples ofspecifically useful diaryl carbonate esters with electron withdrawingsubstituents include bis(4-nitrophenyl)carbonate,bis(2-chlorophenyl)carbonate, bis(4-chlorophenyl)carbonate, bis(methylsalicyl)carbonate, bis(4-methylcarboxylphenyl)carbonate,bis(2-acetylphenyl)carboxylate, bis(4-acetylphenyl)carboxylate, or acombination comprising at least one of the foregoing.

The reactants for the polymerization reaction using an activatedaromatic carbonate can be charged into a reactor either in the solidform or in the molten form. Initial charging of reactants into a reactorand subsequent mixing of these materials under reactive conditions forpolymerization may be conducted in an inert gas atmosphere such as anitrogen atmosphere. The charging of one or more reactants may also bedone at a later stage of the polymerization reaction. Mixing of thereaction mixture is accomplished by any methods known in the art, suchas by stirring. Reactive conditions include time, temperature, pressureand other factors that affect polymerization of the reactants. Typicallythe activated aromatic carbonate is added at a mole ratio of 0.8 to 1.3,and more preferably 0.9 to 1.3, and all sub-ranges there between,relative to the total moles of monomer unit compounds. In a specificembodiment, the molar ratio of activated aromatic carbonate to monomerunit compounds is 1.013 to 1.29, specifically 1.015 to 1.028.

5. BLEND COMPOSITIONS

The cross-linkable polycarbonates of the invention, as described above,can be used in blend compositions. The blend compositions may besubjected to cross-linking conditions (e.g., UV-radiation) to affectcross-linking of the cross-linkable polycarbonates in the blend.Accordingly, blend compositions of the invention include blends prior toand after cross-linking

The blend compositions may comprise one or more distinct cross-linkablepolycarbonates, as described herein, and/or one or more cross-linkedpolycarbonates, as described herein. The blend compositions may compriseone or more additional polymers. The blend compositions may compriseadditional components, such as one or more additives. In certainembodiments, a blend composition comprises a cross-linkable and/orcross-linked polycarbonate of the invention (Polymer A) and a secondpolymer (Polymer B), and optionally one or more additives. In anotherembodiment, a blend composition comprises a combination of across-linkable and/or cross-linked polycarbonate of the invention(Polymer A); and a second polycarbonate (Polymer B), wherein the secondpolycarbonate is different from the first polycarbonate.

In a preferred embodiment, the compositions disclosed herein comprise aflame-retardant/anti-drip agent, a flame retardant additive, and/or animpact modifier. The flame-retardant/anti-drip agent may be potassiumperfluorobutane sulfonate (Rimar salt), potassium diphenylsulfone-3-sulfonate (KSS), or a combination thereof.

(A) First Polymer (Polymer A)

The first polymer (Polymer A) is any cross-linkable or cross-linkedpolycarbonate as described above. The polycarbonate may be, for example,a homopolycarbonate, a copolycarbonate, an isosorbide-containingpolycarbonate, a polyester-polycarbonate, or a polycarbonatepolysiloxane, provided that the cross-linkable polycarbonate comprisesat least some endcap groups derived from a monohydroxybenzophenone. Incertain embodiments, the first polymer does not include soft block orsoft aliphatic segments in the polycarbonate chain.

(B) Second Polymer (Polymer B)

The second polymer (Polymer B) may be any polymer different from thefirst polymer that is suitable for use in a blend composition. Incertain embodiments, the second polymer may be a polycarbonate, apolyester, a polysiloxane, a polyesteramide, a polyimide, apolyetherimide, a polyamideimide, a polyether, a polyethersulfone, apolyepoxide, a polylactide, a polylactic acid (PLA), or any combinationthereof.

In certain embodiments, the second polymer may be a vinyl polymer, arubber-modified graft copolymer, an acrylic polymer, polyacrylonitrile,a polystyrene, a polyolefin, a polyester, a polyesteramide, apolysiloxane, a polyurethane, a polyamide, a polyamideimide, apolysulfone, a polyepoxide, a polyether, a polyimide, a polyetherimide,a polyphenylene ether, a polyphenylene sulfide, a polyether ketone, apolyether ether ketone, an ABS resin, an ASA resin, a polyethersulfone,a polyphenylsulfone, a poly(alkenylaromatic) polymer, a polybutadiene, apolyacetal, a polycarbonate, a polyphenylene ether, an ethylene-vinylacetate copolymer, a polyvinyl acetate, a liquid crystal polymer, anethylene-tetrafluoroethylene copolymer, an aromatic polyester, apolyvinyl fluoride, a polyvinylidene fluoride, a polyvinylidenechloride, tetrafluoroethylene, a polylactide, a polylactic acid (PLA), apolycarbonate-polyorganosiloxane block copolymer, or a copolymercomprising: (i) an aromatic ester, (ii) an estercarbonate, and (iii)carbonate repeat units. The blend composition may comprise additionalpolymers (e.g. a third, fourth, fifth, sixth, etc., polymer).

In certain embodiments, the second polymer may be a homopolycarbonate, acopolycarbonate, a polycarbonate-polysiloxane copolymer, apolyester-polycarbonate, or any combination thereof. In certainembodiments, the second polycarbonate is a p-cumyl phenol cappedpoly(isophthalate-terephthalate-resorcinol ester)-co-(bisphenol-Acarbonate) copolymer. In certain embodiments, the second polycarbonateis a polycarbonate polysiloxane copolymer.

In certain embodiments, the second polymer may be a polycarbonateincorporating one or more repeating units as described in Section2(A)(i) (“Homopolycarbonates/Copolycarbonates”), Section 2(A)(ii)(“Isosorbide-Containing Polycarbonates”), Section 2(A)(iii)(“Polyester-polycarbonates”), and/or Section 2(A)(iv) (“PolycarbonatePolysiloxane Copolymers”).

In one preferred embodiment, the second polymer is a p-cumylphenolcapped poly(19 mol % isophthalate-terephthalate-resorcinol ester)-co-(75mol % bisphenol-A carbonate)-co-(6 mol % resorcinol carbonate) copolymer(MW=29,000 Daltons). In another preferred embodiment, the second polymeris a p-cumylphenol capped poly(10 wt %isophthalate-terephthalate-resorcinol ester)-co-(87 wt % bisphenol-Acarbonate)-co-(3 mol % resorcinol carbonate) copolymer (MW=29,000Daltons). In another preferred embodiment, the second polymer is apolycarbonate polysiloxane copolymer. In another preferred embodiment,the second polymer is a PC-siloxane copolymer with 20% siloxane segmentsby weight. In another preferred embodiment, the second polymer is ap-cumylphenol capped poly(65 mol % BPA carbonate)-co-(35 mol %3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one (PPPBP) carbonate)copolymer (MW=25,000 Daltons).

In another preferred embodiment, the second polymer is a polyphosphonatepolymer, a polyphosphonate copolymer, or a poly(polyphosphonate)-co-(BPAcarbonate) copolymer.

(C) Additives

The compositions may comprise additional components, such as one or moreadditives. Suitable additives include, but are not limited to impactmodifiers, UV stabilizers, colorants, flame retardants, heatstabilizers, plasticizers, lubricants, mold release agents, fillers,reinforcing agents, antioxidant agents, antistatic agents, blowingagents, anti-drip agents, and radiation stabilizers.

(i) Impact Modifiers

The composition may comprise impact modifiers. For example, thecomposition can further include impact modifier(s), with the provisothat the additives are selected so as to not significantly adverselyaffect the desired properties of the composition. Suitable impactmodifiers may be high molecular weight elastomeric materials derivedfrom olefins, monovinyl aromatic monomers, acrylic and methacrylic acidsand their ester derivatives, as well as conjugated dienes. The blendcomposition formed from conjugated dienes can be fully or partiallyhydrogenated. The elastomeric materials can be in the form ofhomopolymers or copolymers, including random, block, radial block,graft, and core-shell copolymers. Combinations of impact modifiers maybe used.

A specific type of impact modifier may be an elastomer-modified graftcopolymer comprising (i) an elastomeric (i.e., rubbery) polymersubstrate having a Tg less than about 10° C., less than about 0° C.,less than about −10° C., or between about −40° C. to −80° C., and (ii) arigid polymer grafted to the elastomeric polymer substrate. Materialssuitable for use as the elastomeric phase include, for example,conjugated diene rubbers, for example polybutadiene and polyisoprene;copolymers of a conjugated diene with less than about 50 wt % of acopolymerizable monomer, for example a monovinylic compound such asstyrene, acrylonitrile, n-butyl acrylate, or ethyl acrylate; olefinrubbers such as ethylene propylene copolymers (EPR) orethylene-propylene-diene monomer rubbers (EPDM); ethylene-vinyl acetaterubbers; silicone rubbers; elastomeric C₁-C₈ alkyl(meth)acrylates;elastomeric copolymers of C₁-C₈ alkyl(meth)acrylates with butadieneand/or styrene; or combinations comprising at least one of the foregoingelastomers. Materials suitable for use as the rigid phase include, forexample, monovinyl aromatic monomers such as styrene and alpha-methylstyrene, and monovinylic monomers such as acrylonitrile, acrylic acid,methacrylic acid, and the C₁-C₆ esters of acrylic acid and methacrylicacid, specifically methyl methacrylate.

Specific impact modifiers include styrene-butadiene-styrene (SBS),styrene-butadiene rubber (SBR), styrene-ethylene-butadiene-styrene(SEBS), ABS (acrylonitrile-butadiene-styrene),acrylonitrile-ethylene-propylene-diene-styrene (AES),styrene-isoprene-styrene (SIS), methyl methacrylate-butadiene-styrene(MBS), and styrene-acrylonitrile (SAN). Exemplary elastomer-modifiedgraft copolymers include those formed from styrene-butadiene-styrene(SBS), styrene-butadiene rubber (SBR),styrene-ethylene-butadiene-styrene (SEBS), ABS(acrylonitrile-butadiene-styrene),acrylonitrile-ethylene-propylene-diene-styrene (AES),styrene-isoprene-styrene (SIS), methyl methacrylate-butadiene-styrene(MBS), and styrene-acrylonitrile (SAN).

MBS may be derived from the following monomers:

SEBS may be a linear triblockcopolymer based on styrene andethylene/butylene. Each copolymer chain may consist of three blocks: amiddle block that is a random ethylene/butylene copolymer surrounded bytwo blocks of polystyrene. The SEBS may bestyrene-b-(ethylene-co-butylene)-b-styrene polymer.

Impact modifiers may be present in amounts of 1 to 30 parts by weight,based on 100 parts by weight of the polymer component of the blendcomposition. Preferred impact modifiers may include MBS and SBS.

In certain embodiments, the compositions do not comprise an impactmodifier.

(ii) UV Stabilizers

The composition may comprise a UV stabilizer for improved performance inUV stabilization. UV stabilizers disperse UV radiation energy.Preferably, when present, the UV stabilizer does not substantiallyhinder or prevent cross-linking of the cross-linkable polycarbonates ofthe invention. Alternatively, in certain embodiments a UV stabilizer maybe used to limit or control the level of cross-linking of thecross-linkable polycarbonate(s) present in the composition.

UV stabilizers may be hydroxybenzophenones, hydroxyphenylbenzotriazoles, cyanoacrylates, oxanilides, and hydroxyphenyl triazines.UV stabilizers may include, but are not limited to,poly[(6-morphilino-s-triazine-2,4-diyl)[2,2,6,6-tetramethyl-4-piperidyl)imino]-hexamethylene[(2,2,6,6-tetramethyl-4-piperidyl)imino],2-hydroxy-4-octyloxybenzophenone (Uvinul®3008),6-tert-butyl-2-(5-chloro-2H-benzotriazole-2-yl)-4-methylphenyl (Uvinul®3026), 2,4-di-tert-butyl-6-(5-chloro-2H-benzotriazole-2-yl)-phenol(Uvinul® 3027), 2-(2H-benzotriazole-2-yl)-4,6-di-tert-pentylphenol(Uvinul® 3028),2-(2H-benzotriazole-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (Uvinul®3029),1,3-bis[(2′-cyano-3′,3′-diphenylacryloyl)oxy]-2,2-bis-{[(2′-cyano-3′,3′-diphenylacryloyl)oxy]methyl}-propane(Uvinul® 3030), 2-(2H-benzotriazole-2-yl)-4-methylphenol (Uvinul® 3033),2-(2H-benzotriazole-2-yl)-4,6-bis(1-methyl-1-phenyethyl)phenol (Uvinul®3034), ethyl-2-cyano-3,3-diphenylacrylate (Uvinul® 3035),(2-ethylhexyl)-2-cyano-3,3-diphenylacrylate (Uvinul® 3039),N,N′-bisformyl-N,N′-bis(2,2,6,6-tetramethyl-4-piperidinyl)hexamethylendiamine(Uvinul® 4050H), bis-(2,2,6,6-tetramethyl-4-piperidyl)-sebacate (Uvinul®4077H),bis-(1,2,2,6,6-pentamethyl-4-piperidyl)-sebacate+methyl-(1,2,2,6,6-pentamethyl-4-piperidyl)-sebacate(Uvinul® 4092H) or combination thereof.

The blend composition may comprise one or more UV stabilizers, includingCyasorb 5411, Cyasorb UV-3638, Uvinul 3030, and/or Tinuvin 234.

It should be recognized that certain monophenolic UV absorbers, whichcan be used as the monohydroxybenzophenone capping agents for thecross-linkable polycarbonates, can be utilized as one or more additives.

In certain embodiments, the composition does not comprise a UVstabilizer.

(iii) Colorants

The composition may comprise colorants such as pigment and/or dyeadditives. Useful pigments may include, for example, inorganic pigmentssuch as metal oxides and mixed metal oxides such as zinc oxide, titaniumdioxides, iron oxides, or the like; sulfides such as zinc sulfides, orthe like; aluminates; sodium sulfo-silicates sulfates, chromates, or thelike; carbon blacks; zinc ferrites; ultramarine blue; organic pigmentssuch as azos, di-azos, quinacridones, perylenes, naphthalenetetracarboxylic acids, flavanthrones, isoindolinones,tetrachloroisoindolinones, anthraquinones, enthrones, dioxazines,phthalocyanines, and azo lakes; Pigment Red 101, Pigment Red 122,Pigment Red 149, Pigment Red 177, Pigment Red 179, Pigment Red 202,Pigment Violet 29, Pigment Blue 15, Pigment Blue 60, Pigment Green 7,Pigment Yellow 119, Pigment Yellow 147, Pigment Yellow 150, and PigmentBrown 24; or combinations comprising at least one of the foregoingpigments. Pigments are generally used in amounts of 0.01 to 10 parts byweight, based on 100 parts by weight of the polymer component of theblend composition.

Exemplary dyes are generally organic materials and include, for example,coumarin dyes such as coumarin 460 (blue), coumarin 6 (green), nile redor the like; lanthanide complexes; hydrocarbon and substitutedhydrocarbon dyes; polycyclic aromatic hydrocarbon dyes; scintillationdyes such as oxazole or oxadiazole dyes; aryl- or heteroaryl-substitutedpoly (C₂-C₈) olefin dyes; carbocyanine dyes; indanthrone dyes;phthalocyanine dyes; oxazine dyes; carbostyryl dyes;napthalenetetracarboxylic acid dyes; porphyrin dyes; bis(styryl)biphenyldyes; acridine dyes; anthraquinone dyes; cyanine dyes; methine dyes;arylmethane dyes; azo dyes; indigoid dyes, thioindigoid dyes, diazoniumdyes; nitro dyes; quinone imine dyes; aminoketone dyes; tetrazoliumdyes; thiazole dyes; perylene dyes, perinone dyes;bis-benzoxazolylthiophene (BBOT); triarylmethane dyes; xanthene dyes;thioxanthene dyes; naphthalimide dyes; lactone dyes; fluorophores suchas anti-stokes shift dyes which absorb in the near infrared wavelengthand emit in the visible wavelength, or the like; luminescent dyes suchas 7-amino-4-methylcoumarin;3-(2′-benzothiazolyl)-7-diethylaminocoumarin;2-(4-biphenylyl)-5-(4-t-butylphenyl)-1,3,4-oxadiazole;2,5-bis-(4-biphenylyl)-oxazole; 2,2′-dimethyl-p-quaterphenyl;2,2-dimethyl-p-terphenyl; 3,5,3″″,5″″-tetra-t-butyl-p-quinquephenyl;2,5-diphenylfuran; 2,5-diphenyloxazole; 4,4′-diphenylstilbene;4-dicyanomethylene-2-methyl-6-(p-dimethylaminostyryl)-4H-pyran;1,1′-diethyl-2,2′-carbocyanine iodide;3,3′-diethyl-4,4′,5,5′-dibenzothiatricarbocyanine iodide;7-dimethylamino-1-methyl-4-methoxy-8-azaquinolone-2;7-dimethylamino-4-methylquinolone-2;2-(4-(4-dimethylaminophenyl)-1,3-butadienyl)-3-ethylbenzothiazoliumperchlorate; 3-diethylamino-7-diethyliminophenoxazonium perchlorate;2-(1-naphthyl)-5-phenyloxazole; 2,2′-p-phenylen-bis(5-phenyloxazole);rhodamine 700; rhodamine 800; pyrene, chrysene, rubrene, coronene, orthe like; or combinations comprising at least one of the foregoing dyes.Dyes are generally used in amounts of 0.01 to 10 parts by weight, basedon 100 parts by weight of the polymer component of the blendcomposition.

(iv) Flame Retardants

The composition may comprise flame retardants. Various types of flameretardants can be utilized as additives. In one embodiment, the flameretardant additives include, for example, flame retardant salts such asalkali metal salts of perfluorinated C₁-C₁₆ alkyl sulfonates such aspotassium perfluorobutane sulfonate (Rimar salt), potassiumperfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate,potassium diphenylsulfone sulfonate (KSS), and the like, sodium benzenesulfonate, sodium toluene sulfonate (NATS) and the like; and saltsformed by reacting for example an alkali metal or alkaline earth metal(for example lithium, sodium, potassium, magnesium, calcium and bariumsalts) and an inorganic acid complex salt, for example, an oxo-anion,such as alkali metal and alkaline-earth metal salts of carbonic acid,such as Na₂CO₃, K₂CO₃, MgCO₃, CaCO₃, and BaCO₃ or fluoro-anion complexsuch as Li₃AlF₆, BaSiF₆, KBF₄, K₃AlF₆, KAlF₄, K₂SiF₆, and/or Na₃AlF₆ orthe like. Rimar salt and KSS and NATS, alone or in combination withother flame retardants, are particularly useful in the compositionsdisclosed herein.

The flame retardants may be selected from at least one of the following:alkali metal salts of perfluorinated C₁-C₁₆ alkyl sulfonates; potassiumperfluorobutane sulfonate; potassium perfluoroctane sulfonate;tetraethylammonium perfluorohexane sulfonate; and potassiumdiphenylsulfone sulfonate.

The flame retardant additives may include organic compounds that includephosphorus, bromine, and/or chlorine.

In certain embodiments, the flame retardant is not a bromine or chlorinecontaining composition. Non-brominated and non-chlorinatedphosphorus-containing flame retardants can be used in certainapplications for regulatory reasons, for example organic phosphates andorganic compounds containing phosphorus-nitrogen bonds. One type ofexemplary organic phosphate is an aromatic phosphate of the formula(GO)₃P═O, wherein each G is independently an alkyl, cycloalkyl, aryl,alkylaryl, or arylalkyl group, provided that at least one G is anaromatic group. Two of the G groups can be joined together to provide acyclic group, for example, diphenyl pentaerythritol diphosphate.Exemplary aromatic phosphates include, phenyl bis(dodecyl) phosphate,phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5′-trimethylhexyl)phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate,bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate,bis(2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate,bis(dodecyl) p-tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyldiphenyl phosphate, p-tolyl bis(2,5,5′-trimethylhexyl) phosphate,2-ethylhexyl diphenyl phosphate, or the like. A specific aromaticphosphate is one in which each G is aromatic, for example, triphenylphosphate, tricresyl phosphate, isopropylated triphenyl phosphate, andthe like.

Di- or poly-functional aromatic phosphorus-containing compounds are alsouseful as additives, for example, compounds of the formulas (35), (36),and (37):

wherein each G¹ is independently a hydrocarbon having 1 to 30 carbonatoms; each G² is independently a hydrocarbon or hydrocarbonoxy having 1to 30 carbon atoms; each X is independently a bromine or chlorine; m is0 to 4, and n is 1 to 30. Exemplary di- or polyfunctional aromaticphosphorus-containing compounds include resorcinol tetraphenyldiphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and thebis(diphenyl) phosphate of bisphenol-A, respectively, their oligomericand polymeric counterparts, and the like.

Exemplary flame retardant additives include phosphonitrilic chloride,phosphorus ester amides, phosphoric acid amides, phosphonic acid amides,phosphinic acid amides, tris(aziridinyl) phosphine oxide,polyorganophosphazenes, and polyorganophosphonates.

The flame retardant additive may have formula (38):

wherein R is a C₁-C₃₆ alkylene, alkylidene or cycloaliphatic linkage,e.g., methylene, ethylene, propylene, isopropylene, isopropylidene,butylene, isobutylene, amylene, cyclohexylene, cyclopentylidene, or thelike; or an oxygen ether, carbonyl, amine, or a sulfur-containinglinkage, e.g., sulfide, sulfoxide, sulfone, or the like. R can alsoconsist of two or more alkylene or alkylidene linkages connected by suchgroups as aromatic, amino, ether, carbonyl, sulfide, sulfoxide, sulfone,or the like.

Ar and Ar′ in formula (38) are each independently mono- orpolycarbocyclic aromatic groups such as phenylene, biphenylene,terphenylene, naphthylene, or the like.

Y is an organic, inorganic, or organometallic radical, for examplehalogen, e.g., chlorine, bromine, iodine, fluorine; ether groups of thegeneral formula OB, wherein B is a monovalent hydrocarbon group similarto X; monovalent hydrocarbon groups of the type represented by R; orother substituents, e.g., nitro, cyano, and the like, said substituentsbeing essentially inert provided that there is greater than or equal toone, specifically greater than or equal to two, halogen atoms per arylnucleus. One or both of Ar and Ar′ may further have one or more hydroxylsubstituents.

When present, each X is independently a monovalent hydrocarbon group,for example an alkyl group such as methyl, ethyl, propyl, isopropyl,butyl, decyl, or the like; an aryl group such as phenyl, naphthyl,biphenyl, xylyl, tolyl, or the like; an aralkyl group such as benzyl,ethylphenyl, or the like; or a cycloaliphatic group such as cyclopentyl,cyclohexyl, or the like. The monovalent hydrocarbon group can itselfcontain inert substituents.

Each d is independently 1 to a maximum equivalent to the number ofreplaceable hydrogens substituted on the aromatic rings comprising Ar orAr′. Each e is independently 0 to a maximum equivalent to the number ofreplaceable hydrogens on R. Each a, b, and c is independently a wholenumber, including 0. When b is not 0, neither a nor c can be 0.Otherwise either a or c, but not both, can be 0. Where b is 0, thearomatic groups are joined by a direct carbon-carbon bond.

The hydroxyl and Y substituents on the aromatic groups, Ar and Ar′ canbe varied in the ortho, meta or para positions on the aromatic rings andthe groups can be in any possible geometric relationship with respect toone another.

Included within the scope of polymeric or oligomeric flame retardantsderived from mono or dihydroxy derivatives of formula (38) are:2,2-bis-(3,5-dichlorophenyl)-propane; bis-(2-chlorophenyl)-methane;bis(2,6-dibromophenyl)-methane; 1,1-bis-(4-iodophenyl)-ethane;1,2-bis-(2,6-dichlorophenyl)-ethane;1,1-bis-(2-chloro-4-iodophenyl)ethane;1,1-bis-(2-chloro-4-methylphenyl)-ethane;1,1-bis-(3,5-dichlorophenyl)-ethane;2,2-bis-(3-phenyl-4-bromophenyl)-ethane;2,6-bis-(4,6-dichloronaphthyl)-propane;2,2-bis-(2,6-dichlorophenyl)-pentane;2,2-bis-(3,5-dibromophenyl)-hexane; bis-(4-chlorophenyl)-phenyl-methane;bis-(3,5-dichlorophenyl)-cyclohexylmethane;bis-(3-nitro-4-bromophenyl)-methane;bis-(4-hydroxy-2,6-dichloro-3-methoxyphenyl)-methane;2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane; and2,2-bis-(3-bromo-4-hydroxyphenyl)-propane. Also included within theabove structural formula are: 1,3-dichlorobenzene, 1,4-dibromobenzene,1,3-dichloro-4-hydroxybenzene, and biphenyls such as2,2′-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene,2,4′-dibromobiphenyl, and 2,4′-dichlorobiphenyl as well as decabromodiphenyl oxide, and the like.

Another useful class of flame retardant is the class of cyclic siloxaneshaving the general formula [(R)₂SiO]y wherein R is a monovalenthydrocarbon or fluorinated hydrocarbon having from 1 to 18 carbon atomsand y is a number from 3 to 12. Examples of fluorinated hydrocarboninclude, but are not limited to, 3-fluoropropyl, 3,3,3-trifluoropropyl,5,5,5,4,4,3,3-heptafluoropentyl, fluorophenyl, difluorophenyl andtrifluorotolyl. Examples of suitable cyclic siloxanes include, but arenot limited to, octamethylcyclotetrasiloxane,1,2,3,4-tetramethyl-1,2,3,4-tetravinylcyclotetrasiloxane,1,2,3,4-tetramethyl-1,2,3,4-tetraphenylcyclotetrasiloxane,octaethylcyclotetrasiloxane, octapropylcyclotetrasiloxane,octabutylcyclotetrasiloxane, decamethylcyclopentasiloxane,dodecamethylcyclohexasiloxane, tetradecamethylcycloheptasiloxane,hexadecamethylcyclooctasiloxane, eicosamethylcyclodecasiloxane,octaphenylcyclotetrasiloxane, and the like. A particularly useful cyclicsiloxane is octaphenylcyclotetrasiloxane.

(v) Heat Stabilizers

The composition may comprise heat stabilizers. Exemplary heat stabilizeradditives include, for example, organophosphites such as triphenylphosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono- anddi-nonylphenyl)phosphite or the like; phosphonates such asdimethylbenzene phosphonate or the like; phosphates such as trimethylphosphate, or the like; or combinations comprising at least one of theforegoing heat stabilizers. Heat stabilizers are generally used inamounts of 0.0001 to 1 part by weight, based on 100 parts by weight ofthe polymer component of the blend composition.

(vi) Plasticizers, Lubricants, Mold Release Agents

The composition may comprise plasticizers, lubricants, and mold releaseagents. Mold release agent (MRA) will allow the material to be removedquickly and effectively. Mold releases can reduce cycle times, defects,and browning of finished product. There is considerable overlap amongthese types of materials, which may include, for example, phthalic acidesters such as dioctyl-4,5-epoxy-hexahydrophthalate;tris-(octoxycarbonylethyl)isocyanurate; tristearin; di- orpolyfunctional aromatic phosphates such as resorcinol tetraphenyldiphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and thebis(diphenyl) phosphate of bisphenol-A; poly-alpha-olefins; epoxidizedsoybean oil; silicones, including silicone oils; esters, for example,fatty acid esters such as alkyl stearyl esters, e.g., methyl stearate,stearyl stearate, pentaerythritol tetrastearate (PETS), and the like;combinations of methyl stearate and hydrophilic and hydrophobic nonionicsurfactants comprising polyethylene glycol polymers, polypropyleneglycol polymers, poly(ethylene glycol-co-propylene glycol) copolymers,or a combination comprising at least one of the foregoing glycolpolymers, e.g., methyl stearate and polyethylene-polypropylene glycolcopolymer in a suitable solvent; waxes such as beeswax, montan wax,paraffin wax, or the like. Such materials are generally used in amountsof 0.001 to 1 part by weight, specifically 0.01 to 0.75 part by weight,more specifically 0.1 to 0.5 part by weight, based on 100 parts byweight of the polymer component of the blend composition.

(vii) Other Filler or Reinforcing Agents

The composition may comprise other fillers or reinforcing agents.Possible fillers or reinforcing agents include, for example, silicatesand silica powders such as aluminum silicate (mullite), syntheticcalcium silicate, zirconium silicate, fused silica, crystalline silicagraphite, natural silica sand, or the like; boron powders such asboron-nitride powder, boron-silicate powders, or the like; oxides suchas TiO₂, aluminum oxide, magnesium oxide, or the like; calcium sulfate(as its anhydride, dihydrate or trihydrate); calcium carbonates such aschalk, limestone, marble, synthetic precipitated calcium carbonates, orthe like; talc, including fibrous, modular, needle shaped, lamellartalc, or the like; wollastonite; surface-treated wollastonite; glassspheres such as hollow and solid glass spheres, silicate spheres,cenospheres, aluminosilicate (armospheres), or the like; kaolin,including hard kaolin, soft kaolin, calcined kaolin, kaolin comprisingvarious coatings known in the art to facilitate compatibility with thepolymeric matrix, or the like; single crystal fibers or “whiskers” suchas silicon carbide, alumina, boron carbide, iron, nickel, copper, or thelike; fibers (including continuous and chopped fibers) such as asbestos,carbon fibers, glass fibers, such as E, A, C, ECR, R, S, D, or NEglasses, or the like; sulfides such as molybdenum sulfide, zinc sulfideor the like; barium compounds such as barium titanate, barium ferrite,barium sulfate, heavy spar, or the like; metals and metal oxides such asparticulate or fibrous aluminum, bronze, zinc, copper and nickel or thelike; flaked fillers such as glass flakes, flaked silicon carbide,aluminum diboride, aluminum flakes, steel flakes or the like; fibrousfillers, for example short inorganic fibers such as those derived fromblends comprising at least one of aluminum silicates, aluminum oxides,magnesium oxides, and calcium sulfate hemihydrate or the like; naturalfillers and reinforcements, such as wood flour obtained by pulverizingwood, fibrous products such as cellulose, cotton, sisal, jute, starch,cork flour, lignin, ground nut shells, corn, rice grain husks or thelike; organic fillers such as polytetrafluoroethylene; reinforcingorganic fibrous fillers formed from organic polymers capable of formingfibers such as poly(ether ketone), polyimide, polybenzoxazole,poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides,aromatic polyimides, polyetherimides, polytetrafluoroethylene, acrylicresins, poly(vinyl alcohol) or the like; as well as additional fillersand reinforcing agents such as mica, clay, feldspar, flue dust, fillite,quartz, quartzite, perlite, tripoli, diatomaceous earth, carbon black,or the like, or combinations comprising at least one of the foregoingfillers or reinforcing agents.

The fillers and reinforcing agents can be coated with a layer ofmetallic material to facilitate conductivity, or surface treated withsilanes to improve adhesion and dispersion with the polymeric matrix. Inaddition, the reinforcing fillers can be provided in the form ofmonofilament or multifilament fibers and can be used individually or incombination with other types of fiber, through, for example, co-weavingor core/sheath, side-by-side, orange-type or matrix and fibrilconstructions, or by other methods known to one skilled in the art offiber manufacture. Exemplary co-woven structures include, for example,glass fiber-carbon fiber, carbon fiber-aromatic polyimide (aramid)fiber, and aromatic polyimide fiberglass fiber or the like. Fibrousfillers can be supplied in the form of, for example, rovings, wovenfibrous reinforcements, such as 0-90 degree fabrics or the like;non-woven fibrous reinforcements such as continuous strand mat, choppedstrand mat, tissues, papers and felts or the like; or three-dimensionalreinforcements such as braids. Fillers are generally used in amounts of0 to 80 parts by weight, based on 100 parts by weight of the polymercomponent of the blend composition.

(viii) Antioxidant Additives

The composition may comprise an antioxidant additive. In certainembodiments, the blend composition does not comprise an antioxidantadditive. Exemplary antioxidant additives include, for example,organophosphites such as tris(nonyl phenyl)phosphite,tris(2,4-di-t-butylphenyl)phosphite (“IRGAFOS 168” or “I-168”),bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, distearylpentaerythritol diphosphite or the like; alkylated monophenols orpolyphenols; alkylated reaction products of polyphenols with dienes,such astetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]methane,or the like; butylated reaction products of para-cresol ordicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenylethers; alkylidene-bisphenols; benzyl compounds; esters ofbeta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid with monohydricor polyhydric alcohols; esters ofbeta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid withmonohydric or polyhydric alcohols; esters of thioalkyl or thioarylcompounds such as distearylthiopropionate, dilaurylthiopropionate,ditridecylthiodipropionate,octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate,pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionateor the like; amides ofbeta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid or the like, orcombinations comprising at least one of the foregoing antioxidants.Antioxidants are generally used in amounts of 0.0001 to 1 part byweight, based on 100 parts by weight of the polymer component of theblend composition.

(ix) Antistatic Agents

The composition may comprise an antistatic agent. Examples of monomericantistatic agents may include glycerol monostearate, glyceroldistearate, glycerol tristearate, ethoxylated amines, primary, secondaryand tertiary amines, ethoxylated alcohols, alkyl sulfates,alkylarylsulfates, alkylphosphates, alkylaminesulfates, alkyl sulfonatesalts such as sodium stearyl sulfonate, sodium dodecylbenzenesulfonateor the like, quaternary ammonium salts, quaternary ammonium resins,imidazoline derivatives, sorbitan esters, ethanolamides, betaines, orthe like, or combinations comprising at least one of the foregoingmonomeric antistatic agents.

Exemplary polymeric antistatic agents may include certainpolyesteramides polyether-polyamide (polyetheramide) block copolymers,polyetheresteramide block copolymers, polyetheresters, or polyurethanes,each containing polyalkylene glycol moieties polyalkylene oxide unitssuch as polyethylene glycol, polypropylene glycol, polytetramethyleneglycol, and the like. Such polymeric antistatic agents are commerciallyavailable, for example PELESTAT® 6321 (Sanyo) or PEBAX® MH1657(Atofina), IRGASTAT® P18 and P22 (Ciba-Geigy). Other polymeric materialsmay be used as antistatic agents are inherently conducting polymers suchas polyaniline (commercially available as PANIPOL®EB from Panipol),polypyrrole and polythiophene (commercially available from Bayer), whichretain some of their intrinsic conductivity after melt processing atelevated temperatures. Carbon fibers, carbon nanofibers, carbonnanotubes, carbon black, or a combination comprising at least one of theforegoing may be used in a polymeric resin containing chemicalantistatic agents to render the composition electrostaticallydissipative. Antistatic agents are generally used in amounts of 0.0001to 5 parts by weight, based on 100 parts by weight of the polymercomponent of the blend composition.

(x) Blowing Agents

The composition may comprise a blowing agent. Foam may be a usefulblowing agent. Low boiling halohydrocarbons and those that generatecarbon dioxide may be used as blowing agents. Blowing agents may be usedthat are solid at room temperature and when heated to temperatureshigher than their decomposition temperature, generate gases such asnitrogen, carbon dioxide, and ammonia gas, such as azodicarbonamide,metal salts of azodicarbonamide, 4,4′ oxybis(benzenesulfonylhydrazide),sodium bicarbonate, ammonium carbonate, or the like, or combinationscomprising at least one of the foregoing blowing agents. Blowing agentsmay be used in amounts of 0.01 to 20 parts by weight, based on 100 partsby weight of the polymer component of the blend composition.

(xi) Anti-Drip Agents

The composition may comprise anti-drip agents. The anti-drip agent maybe a fibril forming or non-fibril forming fluoropolymer such aspolytetrafluoroethylene (PTFE). The anti-drip agent can be encapsulatedby a rigid copolymer as described above, for examplestyrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is knownas TSAN. Encapsulated fluoropolymers can be made by polymerizing theencapsulating polymer in the presence of the fluoropolymer, for examplean aqueous dispersion. TSAN can provide significant advantages overPTFE, in that TSAN can be more readily dispersed in the composition. Anexemplary TSAN can comprise 50 wt % PTFE and 50 wt % SAN, based on thetotal weight of the encapsulated fluoropolymer. The SAN can comprise,for example, 75 wt % styrene and 25 wt % acrylonitrile based on thetotal weight of the copolymer. Alternatively, the fluoropolymer can bepre-blended in some manner with a second polymer, such as for, example,an aromatic polycarbonate or SAN to form an agglomerated material foruse as an anti-drip agent. Either method can be used to produce anencapsulated fluoropolymer. Antidrip agents are generally used inamounts of 0.1 to 5 percent by weight, based on 100 parts by weight ofthe polymer component of the blend composition.

(xii) Radiation Stabilizers

The composition may comprise radiation stabilizers. The radiationstabilizer may be a gamma-radiation stabilizer. Exemplarygamma-radiation stabilizers include alkylene polyols such as ethyleneglycol, propylene glycol, 1,3-propanediol, 1,2-butanediol,1,4-butanediol, meso-2,3-butanediol, 1,2-pentanediol, 2,3-pentanediol,1,4-pentanediol, 1,4-hexandiol, and the like; cycloalkylene polyols suchas 1,2-cyclopentanediol, 1,2-cyclohexanediol, and the like; branchedalkylenepolyols such as 2,3-dimethyl-2,3-butanediol (pinacol), and thelike, as well as alkoxy-substituted cyclic or acyclic alkanes.Unsaturated alkenols are also useful, examples of which include4-methyl-4-penten-2-ol, 3-methyl-pentene-3-ol, 2-methyl-4-penten-2-ol,2,4-dimethyl-4-penten-2-ol, and 9 to decen-1-ol, as well as tertiaryalcohols that have at least one hydroxy substituted tertiary carbon, forexample 2-methyl-2,4-pentanediol (hexylene glycol), 2-phenyl-2-butanol,3-hydroxy-3-methyl-2-butanone, 2-phenyl-2-butanol, and the like, andcyclic tertiary alcohols such as 1-hydroxy-1-methyl-cyclohexane. Certainhydroxymethyl aromatic compounds that have hydroxy substitution on asaturated carbon attached to an unsaturated carbon in an aromatic ringcan also be used. The hydroxy-substituted saturated carbon can be amethylol group (—CH₂OH) or it can be a member of a more complexhydrocarbon group such as —CR²⁴HOH or —CR²⁴ ₂OH wherein R²⁴ is a complexor a simple hydrocarbon. Specific hydroxy methyl aromatic compoundsinclude benzhydrol, 1,3-benzenedimethanol, benzyl alcohol, 4-benzyloxybenzyl alcohol and benzyl benzyl alcohol. 2-Methyl-2,4-pentanediol,polyethylene glycol, and polypropylene glycol are often used forgamma-radiation stabilization. Gamma-radiation stabilizing compounds aretypically used in amounts of 0.1 to 10 parts by weight based on 100parts by weight of the polymer component of the blend composition.

In certain embodiments, the composition does not comprise a radiationstabilizer.

6. METHOD OF MAKING THE COMPOSITIONS

The compositions disclosed herein, blends or neat, can be manufacturedby various methods. For example, a neat or blend composition may befirst mixed in a high speed HENSCHEL-Mixer®. Other low shear processes,including but not limited to hand mixing, can also accomplish thisblending. The mixed composition may then be fed into the throat of asingle or twin-screw extruder via a hopper. Alternatively, at least oneof the components can be incorporated into the composition by feedingdirectly into the extruder at the throat and/or downstream through aside-stuffer. Additives can also be compounded into a master-batch witha desired polymeric resin and fed into the extruder. The extruder may begenerally operated at a temperature higher than that necessary to causethe composition to flow. The extrudate may be immediately quenched in awater batch and pelletized. The pellets, so prepared, when cutting theextrudate can be one-fourth inch long or less as desired. Such pelletscan be used for subsequent molding, shaping, or forming.

7. ARTICLES

Compositions disclosed herein, preferably prior to cross-linking, may beformed, shaped, molded, injection molded, or extruded into an article.The compositions can be molded into useful shaped articles by a varietyof means such as injection molding, overmolding, co-injection molding,extrusion, multilayer extrusion, rotational molding, blow molding andthermoforming to form articles. The formed articles may be subsequentlysubjected to cross-linking conditions (e.g., UV-radiation) to affectcross-linking of the polycarbonates comprising monohydroxybenzophenonederived endcap.

Articles that may be formed from the compositions include variouscomponents for cell phones and cell phone covers, components forcomputer housings, computer housings and business machine housings andparts such as housings and parts for monitors, computer routers,copiers, desk top printers, large office/industrial printers handheldelectronic device housings such as computer or business machinehousings, housings for hand-held devices, components for light fixturesor home or office appliances, humidifier housings, thermostat controlhousings air conditioner drain pans, outdoor cabinets, telecomenclosures and infrastructure, Simple Network Intrusion Detection System(SNIDS) devices, network interface devices, smoke detectors, componentsand devices in plenum spaces, components for medical applications ordevices such as medical scanners, X-ray equipment, and ultrasounddevices, components for interior or exterior components of anautomobile, lenses (auto and non-auto) such as components for filmapplications, greenhouse components, sun room components, fire helmets,safety shields, safety goggles, glasses with scratch resistance andimpact resistance, fendors, gas pumps, films for televisions, such asecofriendly films having no halogen content, solar applicationmaterials, glass lamination materials, fibers for glassed filledsystems, turbine blades (e.g., wind turbines), and the like.

In certain embodiments, articles that may comprise the compositioninclude automotive bumpers, other automotive, construction andagricultural equipment exterior components, automobile mirror housings,automobile wheel covers, automobile, construction and agriculturalequipment instrument panels and trim, automobile glove boxes, automobiledoor hardware and other interior trim, automobile construction andagricultural equipment exterior lights, automobile parts within theengine compartment, plumbing equipment, valves and pumps, airconditioning heating and cooling parts, furnace and heat pump parts,computer parts, electronics parts, projector parts, electronic displayparts, copier parts, scanner parts, electronic printer toner cartridges,hair driers, irons, coffee makers, toasters, washing machines,microwaves, ovens, power tools, electric components, lighting parts,dental instruments and equipment, medical instruments, cookware, medicalinstrument trays, animal cages, fibers, laser welded medical devices,and fiber optics.

In certain embodiments, articles that may comprise the compositioninclude automotive bumpers, other automotive exterior components,automobile mirror housings, automobile wheel covers, automobileinstrument panels and trim, automobile glove boxes, automobile doorhardware and other interior trim, external automobile trim parts, suchas pillars, automobile exterior lights, automobile parts within theengine compartment, an agricultural tractor or device part, aconstruction equipment vehicle or device part, a marine or personalwater craft part, an all terrain vehicle or all terrain vehicle part,plumbing equipment, valves and pumps, air conditioning heating andcooling parts, furnace and heat pump parts, computer parts, electronicsparts, projector parts, electronic display parts, copier parts, scannerparts, electronic printer toner cartridges, hair driers, irons, coffeemakers, toasters, washing machines, microwaves, ovens, power tools,electric components, electric enclosures, lighting parts, dentalinstruments, medical instruments, medical or dental lighting parts, anaircraft part, a train or rail part, a seating component, sidewalls,ceiling parts, cookware, medical instrument trays, animal cages, fibers,laser welded medical devices, fiber optics, lenses (auto and non-auto),cell phone parts, greenhouse components, sun room components, firehelmets, safety shields, safety glasses, gas pump parts, and turbineblades.

In certain embodiments, the article is one that requires or must includea material having a UL94 5VA rating performance. Articles that require aUL94 5VA rating include, but are not limited to, computer housings,computer housings and business machine housings and parts such ashousings and parts for monitors, computer routers, copiers, desk topprinters, large office/industrial printers, handheld electronic devicehousings such as computer or business machine housings, housings forhand-held devices, components for light fixtures including LED fixturesor home or office appliances, humidifier housings, thermostat controlhousings, air conditioner drain pans, outdoor cabinets, telecomenclosures and infrastructure, Simple Network Intrusion Detection System(SNIDS) devices, network interface devices, smoke detectors, componentsand devices in plenum spaces, components for medical applications ordevices such as medical scanners, X-ray equipment, and ultrasounddevices, electrical boxes and enclosures, and electrical connectors.

In certain embodiments, the article is one that requires hydrothermalstability, such as a wind turbine blade, a steam sterilizable medicaldevice, a food service tray, utensiles and equipment.

In certain embodiments, the article is one that requires a combinationof transparency, flame resistance, and/or impact resistance. Forexample, in certain embodiments the article may be a safety shield,safety goggles, a gas/fuel pump housing, a display window or part, orthe like.

8. METHOD OF MAKING THE ARTICLES

The article may be produced by a manufacturing process. The process maycomprise the steps of (a) providing a composition comprising one or morepolymers as described above, wherein at least one of the polymers is across-linkable polycarbonate comprising monohydroxybenzophenone derivedendcaps, as described above. The composition from step (a) may then be(b) melted, for example, at 200-400° C., 225-350° C., 250-310° C., or270-300° C. in an extruder. The melted composition of step (b) may thenbe (c) extruded, and (d) the composition may be isolated or chopped. Thearticle of manufacture may further be produced by the step of (e) dryingthe composition and (f) melt forming the composition. The article maythen be subjected to cross-linking conditions, as described herein, soas to affect cross-linking of the polycarbonate comprisingmonohydroxybenzophenone derived endcaps. In certain embodiments, thearticle is not subjected to cross-linking conditions immediately aftermanufacture, but rather is cross-linked at a later time, such as whenthe article is introduced to sun light.

The present invention has multiple aspects, illustrated by the followingnon-limiting examples.

9. EXAMPLES

All solvents and reagents used were analytical grade.

Molecular weight determinations were performed using gel permeationchromatography (GPC), using a cross-linked styrene-divinylbenzene columnand calibrated to polycarbonate references using a UV-VIS detector setat 264 nm. Samples were prepared at a concentration of about 1 mg/ml,and eluted at a flow rate of about 1.0 ml/min.

Differential scanning calorimetry (DSC) employing a temperature sweeprate of 20° C./min was used to determine glass transition temperaturesof polycarbonates.

(A) Preparation of Cross-Linkable Polycarbonates Example 14-Hydroxybenzophenone endcapped polycarbonate “Benzophenone-BPACopolymer—0.5 mol %—23 k”

The following were added into a 2 liter glass reactor equipped with anoverhead condenser, a phosgene inlet and a pH probe allowing monitoringpH during the course of the reaction: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (30 g, 131.6 mmol); (b)4-hydroxybenzophenone (0.13 g, 0.7 mmol); (c) para-cumylphenol (0.7 g,3.3 mmol); (d) triethylamine (0.18 g, 1.3 mmol); (e) methylene chloride(500 mL); (f) de-ionized water (300 mL). The reaction was allowed tostir for 10 minutes and the pH was maintained at pH=8 by the addition of30 wt-% NaOH solution. The mixture was charged with phosgene (18.6 g, 2g/min, 0.188 mol). During the addition of phosgene, base (30 wt-% NaOHin deionized water) was simultaneously charged to the reactor tomaintain the pH of the reaction between 9-10. After the completeaddition of phosgene, the reaction was purged with nitrogen gas, and theorganic layer was extracted. The organic extract was washed once withdilute hydrochloric acid (HCl), and subsequently washed with de-ionizedwater three times. The organic layer was precipitated from methylenechloride into hot water. The polymer was dried in an oven at 110° C.before analysis. Gel permeation chromatography (GPC) allowed for adetermination of the molecular weight of the resulting polymer. The Mwof the polycarbonate was measured to be 22,877 Daltons (referenced topolycarbonate standards) and polydispersity index=3.11.

Example 2 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—2.5 mol %—30 k”

The following were added into a 2 liter glass reactor equipped with anoverhead condenser, a phosgene inlet and a pH probe allowing monitoringpH during the course of the reaction: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (30 g, 131.6 mmol); (b)4-hydroxybenzophenone (0.65 g, 3.3 mmol); (c) para-cumylphenol (0.14 g,0.7 mmol); (d) triethylamine (0.18 g, 1.3 mmol); (e) methylene chloride(500 mL); (f) de-ionized water (300 mL). The reaction was allowed tostir for 10 minutes and the pH was maintained at pH=8 by the addition of30 wt-% NaOH solution. The mixture was charged with phosgene (18.74 g, 2g/min, 0.189 mol). During the addition of phosgene, base (30 wt-% NaOHin deionized water) was simultaneously charged to the reactor tomaintain the pH of the reaction between 9-10. After the completeaddition of phosgene, the reaction was purged with nitrogen gas, and theorganic layer was extracted. The organic extract was washed once withdilute hydrochloric acid (HCl), and subsequently washed with de-ionizedwater three times. The organic layer was precipitated from methylenechloride into hot water. The polymer was dried in an oven at 110° C.before analysis. Gel permeation chromatography (GPC) allowed for adetermination of the molecular weight of the resulting polymer. The Mwof the polycarbonate was measured to be 30,255 Daltons (referenced topolycarbonate standards) and polydispersity index=2.09.

Example 3 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—1.7 mol %—28 k”

The following were added into a 70 L continuous stirred-tank reactor(CSTR) equipped with an overhead condenser and a recirculation pump witha flow rate of 40 L/minute: (a) 4,4-bis-(hydroxyphenyl)-2,2-propane(BPA) (4000 g, 17.52 mol); (b) 4-hydroxybenzophenone (59 g, 0.297 mol);(c) para-cumylphenol (45 g, 0.212 mol); (d) triethylamine (42 mL, 0.415mol); (e) methylene chloride (23.4 L); (f) de-ionized water (10.8 L),and (g) sodium gluconate (10 g). The reaction was allowed to stir for 10minutes and the pH was maintained at pH=9 by the addition of 30% NaOHsolution. The mixture was charged with phosgene (2500 g, 80 g/min, 25.3mol). During the addition of phosgene, base (30 wt % NaOH in deionizedwater) was simultaneously charged to the reactor to maintain the pH ofthe reaction between 8.5-9. After the complete addition of phosgene, thereaction was purged with nitrogen gas, and the organic layer wasextracted. The organic extract was washed once with dilute hydrochloricacid (HCl), and subsequently washed with de-ionized water three times.The organic layer was precipitated from methylene chloride into hotsteam. The polymer was dried in an oven at 110° C. before analysis. TheMw of the polycarbonate was measured to be 28,366 Daltons (referenced topolycarbonate standards) and polydispersity index=3.78.

Example 4 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—2.5 mol %—27 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (87 g, 0.438 mol); (c) para-cumylphenol (28 g,0.132 mol); (d) triethylamine (60 mL, 0.593 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2500 g, 80 g/min, 25.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 27,106 Daltons (referenced to polycarbonatestandards) and polydispersity index=6.19.

Example 5 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—0.5 mol %—28 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (18 g, 0.09 mol); (c) para-cumylphenol (105 g,0.494 mol); (d) triethylamine (60 mL, 0.593 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2500 g, 80 g/min, 25.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 27,482 Daltons (referenced to polycarbonatestandards) and polydispersity index=3.40.

Example 6 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—0.5 mol %—24 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (18 g, 0.09 mol); (c) para-cumylphenol (120 g,0.565 mol); (d) triethylamine (60 mL, 0.593 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2500 g, 80 g/min, 25.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 24,379 Daltons (referenced to polycarbonatestandards) and polydispersity index=3.30.

Example 7 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—0.5 mol %—21 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (18 g, 0.09 mol); (c) para-cumylphenol (148 g,0.697 mol); (d) triethylamine (60 mL, 0.593 mol); (e) methylene chloride(24.4 L); (f) de-ionized water (10.8 L), and (g) sodium gluconate (10g). The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2500 g, 80 g/min, 25.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 21,171 Daltons (referenced to polycarbonatestandards) and polydispersity index=3.22.

Example 8 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—2.5 mol %—26 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (87 g, 0.438 mol); (c) para-cumylphenol (35 g,0.165 mol); (d) triethylamine (80 mL, 0.79 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2700 g, 80 g/min, 27.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 25,916 Daltons (referenced to polycarbonatestandards) and polydispersity index=5.21.

Example 9 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—2.5 mol %—27 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (18 g, 0.09 mol); (c) para-cumylphenol (105 g,0.49 mol); (d) triethylamine (60 mL, 0.59 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2700 g, 80 g/min, 27.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 27,055 Daltons (referenced to polycarbonatestandards) and polydispersity index=3.19.

Example 10 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—0.5 mol %—27 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (18 g, 0.09 mol); (c) para-cumylphenol (148 g,0.698 mol); (d) triethylamine (42 mL, 0.41 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2700 g, 80 g/min, 27.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 27,256 Daltons (referenced to polycarbonatestandards) and polydispersity index=3.23.

Example 11 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—0.5 mol %—26 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (87 g, 0.439 mol); (c) para-cumylphenol (35 g,0.165 mol); (d) triethylamine (42 mL, 0.41 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2700 g, 80 g/min, 27.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 25,999 Daltons (referenced to polycarbonatestandards) and polydispersity index=6.98.

Example 12 4-Hydroxybenzophenone endcapped polycarbonate“Benzophenone-BPA Copolymer—0.5 mol %—27 k”

The following were added into a 70 L CSTR equipped with an overheadcondenser and a recirculation pump with a flow rate of 40 L/minute: (a)4,4-bis-(hydroxyphenyl)-2,2-propane (BPA) (4000 g, 17.52 mol); (b)4-hydroxybenzophenone (87 g, 0.439 mol); (c) para-cumylphenol (28 g,0.132 mol); (d) triethylamine (42 mL, 0.41 mol); (e) methylene chloride(23 L); (f) de-ionized water (10 L), and (g) sodium gluconate (10 g).The reaction was allowed to stir for 10 minutes and the pH wasmaintained at pH=9 by the addition of 30% NaOH solution. The mixture wascharged with phosgene (2700 g, 80 g/min, 27.3 mol). During the additionof phosgene, base (30 wt % NaOH in deionized water) was simultaneouslycharged to the reactor to maintain the pH of the reaction between 8.5-9.After the complete addition of phosgene, the reaction was purged withnitrogen gas, and the organic layer was extracted. The organic extractwas washed once with dilute hydrochloric acid (HCl), and subsequentlywashed with de-ionized water three times. The organic layer wasprecipitated from methylene chloride into hot steam. The polymer wasdried in an oven at 110° C. before analysis. The Mw of the polycarbonatewas measured to be 27,084 Daltons (referenced to polycarbonatestandards) and polydispersity index=7.26.

Table 1 summarizes the constituents and the weight average molecularweights of the polycarbonates of Examples 1-12.

TABLE 1 Ex. # Component Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 Ex. 8Ex. 9 Ex. 10 Ex. 11 Ex. 12 BPA 30 g 30 g 4 kg 4 kg 4 kg 4 kg 4 kg 4 kg 4kg 4 kg 4 kg 4 kg HBP 0.13 g 0.65 g 59 g 87 g 18 g 18 g 18 g 87 g 87 g18 g 18 g 18 g PCP 0.7 g 0.14 g 45 g 28 g 105 g 120 g 148 g 35 g 105 g105 g 35 g 28 g Na glu — — 10 g 10 g 10 g 10 g 10 g 10 g 10 g 10 g 10 g10 g NEt₃ 0.18 g 0.18 g 42 mL 60 mL 60 mL 60 mL 60 mL 80 mL 60 mL 60 mL42 mL 42 mL phosgene 18.6 g 18.74 g 2.5 kg 2.5 kg 2.5 kg 2.5 kg 2.5 kg2.7 kg 2.7 kg 2.7 kg 2.7 kg 2.7 kg water 300 mL 300 mL 10.8 L 10 L 10 L10 L 10.8 L 10 L 10 L 10 L 10 L 10 L CH₂Cl₂ 500 mL 500 mL 23.4 L 23 L 23L 23 L 24.4 L 23 L 23 L 23 L 23 L 23 L Mw, 22,877 30,255 28,366 27,10627,482 24,379 21,171 25,916 27,055 27,256 25,999 27,084 Daltons PDI — —3.78 6.19 3.40 3.30 3.22 5.21 3.19 3.23 6.98 7.26 mol % HBP 0.5% 2.5%1.7% 2.5% 0.5% 0.5% 0.5% 2.5% 2.5% 0.5% 0.5% 0.5% endcap BPA =bispnenol-A; HBP = 4-hydroxybenzophenone; PCP = p-cumylphenol; Na glu =sodium gluconate; NEt₃ = triethyl amine; CH₂Cl₂ = methylene chloride;PDI = polydispersity index

The 4-hydroxybenzophenone endcapped polycarbonates of Examples 1-12 wereprepared as compositions optionally using one or more of the componentsshown in Table 2. Comparative Examples were also prepared using thecomponents of Table 2. The referenced compositions were prepared bymixing together the selected constituents and preblending. Extrusion andmolding was carried out under normal polycarbonate processingconditions.

TABLE 2 Trade name, Component Description Source 20:80 ITR- Poly(19 mol% isophthalate-terephthalate- SABIC-IP PC resorcinol ester)-co-(75 mol %bisphenol-A carbonate)-co-(6 mol % resorcinol carbonate) copolymer (Mw =31,000, PC standards) HF-PC or Bisphenol-A based polycarbonate resinSABIC-IP High-Flow (Mw = 22,000 Daltons, PC standards) PC LF-PC orBisphenol-A based polycarbonate resin SABIC-IP Low-Flow (Mw = 30,000Daltons, PC standards) PC KSS Potassium diphenylsulphon-3-sulphonateArichem LLC Rimar Salt Potassium perfluorobutanesulfonate Lanxess PETSpentaerythritol tetrastearate Faci UV2-(2′-hydroxy-5′-t-octylphenyl)benzo- CYASORB stabilizer triazole UV5411, Cytec Heat Tetrakis(2,4-di-tert-butylphenyl)-4,4′- PEPQ, Cibastabilizer biphenylenediphosphonite Specialty Chemicals HydrolyticCycloaliphatic Epoxy Resin, 3,4-epoxy ERL4221, stabilizer cyclohexylmethyl-3,4-epoxy cyclohexyl Various carboxylate Colorant 1 Colorant 2Phosphite Tris (2,4-di-tert-butylphenyl) phosphite Irgaphos Stabilzer168 Hindered Phenol

(B) Cross-Linking Results

Compositions of the 4-hydroxybenzophenone endcapped polycarbonates ofExamples 1-12 were cross-linked with ultra-violet (UV) radiation. Thepolycarbonate compositions were treated with ultra-violet radiationgenerated from a UV-lamp, or irradiative energy (including UV) receivedupon sun exposure.

(i) Cross-Linking of 4-hydroxybenzophenone Endcapped PolycarbonatesUsing a UV-Lamp

Ultra-violet radiation was used to cross-link the neat resincompositions of Examples 1 and 2. First, films of Examples 1 and 2 wereformed by melt-pressing the corresponding powder at 550° F. Thethickness of each film was about 0.5 mm. Each film was then irradiatedwith UV-radiation emitted from a 9 mm D bulb having outputspecifications of about 796.5 Watts from 201 nm to 600 nm, as shown inTable 3. The time of irradiation was 90 seconds, providing an energy ofirradiation of 3,000 mJ/cm² measured using a UV Power Puck™ aletro-opticradiometer.

TABLE 3 Interval Power (nm) (Watts) 201-210 2.3 211-220 4.2 221-230 4.9231-240 5.8 241-250 10.8 251-260 17.7 261-270 13.6 271-280 20.3 281-29011.6 291-300 24.3 301-310 28.6 311-320 21.5 321-330 21.0 331-340 11.0341-350 24.4 351-360 50.8 361-370 57.5 371-380 74.9 381-390 72.2 391-40027.9 401-410 30.6 411-420 26.2 421-430 34.8 431-440 40.4 441-450 19.5451-460 4.9 461-470 3.5 471-480 2.7 481-490 9.0 491-500 15.3 501-510 7.2511-520 12.7 521-530 16.7 531-540 17.2 541-550 27.3 551-560 5.3 561-5703.8 571-580 8.7 581-590 3.4 591-600 2.2

Table 4 demonstrates the progression of molecular weight as a functionof irradiation time of Example 1 and Example 2. These data show that themolecular weight of each film increased dramatically as a function of UVdosage. The data shows also that the more 4-hydroxybenzophenone endcappresent in the resin, the greater is the molecular weight increase, asExample 2 (2.5 mol % HBP endcap) showed a 144% increase in molecularweight after 5 passes under the UV-lamp, compared with a 30% increase inmolecular weight for Example 1 (0.5 mol % HBP endcap) after 5 passes.

TABLE 4 Unit Example 1 Example 2 4-Hydroxybenzophenone amount mol-% 0.52.5 Untreated film MW Daltons 22,877 30,255 1 pass UV-treated film MWDaltons 25,784 53,346 5 pass UV-treated film MW Daltons 29,664 73,945 MWincrease after 5 passes % 30 144

FIGS. 1 and 2 also demonstrate the progression of molecular weight as afunction of irradiation time for 4-hydroxybenzophenone endcappedpolycarbonates of the invention. The figures show molecular weightprogression upon cross-linking of 4-hydroxybenzophenone-BPApolycarbonates at 0.5 mol % hydroxybenzophenone endcap, 1.5 mol %hydroxybenzophenone endcap, and 2.5 mol % hydroxybenzophenone endcap.Each of the three polycarbonates included sufficient p-cumylphenolendcap to bring the total endcap mol % to 3 mol %.

The cross-linking reaction of Example 2 (benzophenone-BPA copolymer—2.5mol %—30 k) was monitored by ¹H-nuclear magnetic resonance spectroscopy(NMR), as shown in FIGS. 3 and 4. Without being bound by theory, it isbelieved that cross-linking occurs between benzophenone carbonyl carbonatoms and methyl carbon atoms as found in repeating bisphenol-A units.The cross-linking reaction can be monitored by following the peakintensity increase at 3.48 ppm in the NMR spectrum of the composition,which peak corresponds to the methylene hydrogens at the newly formedcarbon-carbon bond. FIGS. 3 and 4 illustrate that with each pass underthe UV-lamp, the peak intensity increased at 3.48 ppm, indicatingprogression of the cross-linking process.

(ii) Cross-Linking of 4-hydroxybenzophenone Endcapped Polycarbonates ViaSun Exposure

Sun exposure was used to cross-link the polycarbonates. Films wereformed of the cross-linkable polycarbonates by melt-pressing thecorresponding powder at 550° F. The thickness of each film was about 0.5mm. Each film was then exposed to UV-radiation emitted from the sun overa period of 360 hours.

Table 5, shown below, and FIG. 5 demonstrate that upon exposure toirradiative energy from the sun, the 4-hydroxybenzophenone endcappedpolycarbonates underwent cross-linking and an increase in molecularweight. Accordingly, sun exposure can be used as a method ofcross-linking the herein disclosed polycarbonates comprisingmonohydroxybenzophenone derived endcaps.

The % Gel data indicates the extent of crosslinking as function of thesun exposure time. The % Gel is measured by dividing the weight of thecrosslinked portion of the exposed material by the total weight of thesample. The crosslinked portion corresponds to the insoluble part of thesample soaked in methylene chloride for 12 hours. This data shows thathigher the amount of HBP, greater will be the amount of crosslinkedmaterial after sun exposure.

TABLE 5 Sun Exposure Time (Hours) HBP 0 4 24 48 72 144 360 Delta MW (%)MW MW MW MW MW MW MW (%) % Gel 0.5 21620 25900 25098 25324 25703 2620226013 16 0 0.5 26118 31130 33305 36826 32371 35363 34994 28 1 0.5 2754931145 34172 36231 34756 36235 36517 24 1 2.5 25458 41086 59852 6074560224 69605 78980 135 15 2.5 24245 46183 79350 65228 67150 45841 58211227 27 2.5 26145 45112 64941 51008 63437 63819 34831 148 52 HBP =hydroxybenzophenone; MW = Molecular Weight

(C) Flame Resistance

Flammability tests were performed following the procedure ofUnderwriter's Laboratory Bulletin 94 entitled “Tests for Flammability ofPlastic Materials, UL94”. Several ratings can be applied based on therate of burning, time to extinguish, ability to resist dripping, andwhether or not drips are burning. According to this procedure, materialsmay be classified as HB, V0, V1, V2, 5V, 5VA and/or 5VB on the basis ofthe test results obtained for five samples. The criteria for theflammability classifications or “flame retardance” are described below.

V0: A specimen is supported in a vertical position and a flame isapplied to the bottom of the specimen. The flame is applied for tenseconds and then removed until flaming stops at which time the flame isreapplied for another ten seconds and then removed. Two sets of fivespecimens are tested. The two sets are conditioned under differentconditions.

To achieve a V0 rating, specimens must not burn with flaming combustionfor more than 10 seconds after either test flame application. Totalflaming combustion time must not exceed 50 seconds for each set of 5specimens. Specimens must not burn with flaming or glowing combustion upto the specimen holding clamp. Specimens must not drip flaming particlesthat ignite the cotton. No specimen can have glowing combustion remainfor longer than 30 seconds after removal of the test flame

5VA: Testing is done on both bar and plaque specimens. Procedure forBars: A bar specimen is supported in a vertical position and a flame isapplied to one of the lower corners of the specimen at a 20° angle. Theflame is applied for 5 seconds and is removed for 5 seconds. The flameapplication and removal is repeated five times. Procedure for Plaques:The procedure for plaques is the same as for bars except that the plaquespecimen is mounted horizontally and a flame is applied to the center ofthe lower surface of the plaque.

To achieve a 5VA rating, specimens must hot have any flaming or glowingcombustion for more than 60 seconds after the five flame applications.Specimens must not drip flaming particles that ignite the cotton. Plaquespecimens must not exhibit burnthrough (a hole).

Compositions comprising cross-linked polycarbonates disclosed herein(neat and blended) were evaluated for UL 94 V0 and 5VA performance ascompared to high-flow BPA-polycarbonate neat and blended compositions.The tested compositions and flame test results are provided in Tables6-9, shown below.

(i) V0 Performance

Flammability testing was conducted on flame bars prepared fromcompositions labelled as Sample 1 (51), Comparative Sample 2 (CS2),Sample 3 (S3), and Comparative Sample 4 (CS4), described in Table 6. S1is a blend composition comprising the benzophenone-BPA copolymer ofExample 8 and a p-cumylphenol capped poly(20 wt %isophthalate-terephthalate-resorcinol ester)-co-(80 wt % bisphenol-Acarbonate) copolymer. CS2 is a blend composition comprising a high-flowBPA-polycarbonate and a p-cumylphenol capped poly(20 wt %isophthalate-terephthalate-resorcinol ester)-co-(80 wt % bisphenol-Acarbonate) copolymer. S3 is a neat resin composition comprising thebenzophenone-BPA copolymer of Example 8. CS4 is a neat resin compositioncomprising the high-flow BPA-polycarbonate.

TABLE 6 Sample Ingredient Unit S1 CS2 S3 CS4 Example 8 Benzophenone-BPAcopolymer - 2.5 mol-% - 26k % 55 100 20:80 p-cumylphenol capped poly(20wt % isophthalate- % 45 45 ITR-PC terephthalate-resorcinol ester)-co-(80wt % bisphenol-A carbonate) copolymer (Mw = 60,000, PS standards) HF-PCBisphenol-A based polycarbonate resin (Mw = 22,000 % 55 100 Daltons, PSstandards) UV 2-(2′-hydroxy-5′-t-octylphenyl)benzotriazole % 0.20 0.200.20 0.20 stabilizer PEPQ Phosphonous Acid Ester (CAS # 119345-01-6) %0.06 0.06 0.06 0.06 Powder Cycloaliphatic Epoxy Resin (3,4-epoxycyclohexyl % 0.03 0.03 0.03 0.03 methyl-3,4-epoxy cyclohexylcarboxylate), ERL4221 KSS Potassium diphenylsulphon-3-sulphonate % 0.030.03 0.03 0.03 PETS pentaerythritol tetrastearate % 0.30 0.30 0.30 0.30Colorant 1 % 0.13 0.13 0.13 0.13 Colorant 2 % 0.13 0.13 0.13 0.13 MVRMelt Volume Flow Rate cc/10 9.5 15.9 8.1 25.9 min Abusive Abusive MeltVolume Flow Rate cc/10 11.4 21.7 8.5 27.7 MVR min

Flammability testing was conducted using the standard UnderwritersLaboratory UL 94 test method (7 day conditioning), except that 20 barsrather than the usual 5 bars were tested. Specimens are to bepreconditioned in an air-circulating oven for 168 hours at 70±1° C. andthen cooled in a desiccator for at least 4 hours at room temperature,prior to testing. Once removed from the desiccator, specimens are testedwithin 30 minutes. The data was analyzed by calculation of the averageflame out time, standard deviation of the flame out time and the totalnumber of drips. Statistical methods were used to convert the data to aprobability that a specific formulation would achieve a first time V0pass or “p(FTP)” in the standard UL 94 testing of 5 bars. Preferablyp(FTP) values will be 1 or very close to 1 for high confidence that asample formulation would achieve a V0 rating in UL 94 testing.

Table 7 presents p(FTP) values for the blend (51) comprising thebenzophenone-BPA copolymer and the p-cumylphenol capped ITR-PC; and theneat benzophenone-BPA copolymer (S3). p(FTP) values are provided forboth before and after the flame bars are exposed to UV radiation. Theresults from 51 and S3 are compared with results from flame barsprepared from the blend (CS2) comprising the high-flow BPA polycarbonateand the p-cumylphenol capped ITR-PC; and the neat high-flowBPA-polycarbonate (CS4). S3 and CS4 were prepared in order to comparethe flame behavior of the blends of S1 and CS2 with neat resincompositions. Potassium sulfone sulfonate was incorporated into thetested compositions as a flame poison.

TABLE 7 Sample S1 CS2 (blend) (blend) S3 CS4 Flame (HBP-BPA/ (HF-BPA/(neat) (neat) Resistance ITR-PC) ITR-PC) (HBP-BPA) (HF-BPA) Beforep(FTP) @ 0 0 0 0 UV 2.00 mm After p(FTP) @ 0.99 0 0.8 0 UV 2.00 mmp(FTP) @ 0.2 0 0.3 — 1.50 mm p(FTP) @ 0.1 0 — — 1.00 mm HBP-BPA =Benzophenone-BPA copolymer - 2.5 mol-% - 26k; HF-BPA = High-FlowBisphenol-A based polycarbonate resin; HBP-BPA/ITR-PC = Benzophenone-BPAcopolymer - 2.5 mol-% - 26k/p-cumylphenol capped poly(20 wt %isophthalate-terephthalate-resorcinol ester)-co-(80 wt % bisphenol-Acarbonate) copolymer; HF-BPA/ITR-PC = High-Flow Bisphenol-A basedpolycarbonate resin/p-cumylphenol capped poly(20 wt %isophthalate-terephthalate-resorcinol ester)-co-(80 wt % bisphenol-Acarbonate) copolymer.

The data of Table 7 shows a dramatic increase of the p(FTP) values forthe UV-treated compositions incorporating 4-hydroxybenzophenone endcap,whereas the corresponding controls with the high-flow polycarbonate donot show any variation in their respective probability values.Surprisingly, even in blends, the cross-linked benzophenone-BPAcopolymers impart V0 performance to the test bars at 2 mm thickness.

(ii) 5VA Performance

Flammability testing was conducted on flame bars and plaques preparedfrom compositions labelled as Sample 5 (S5), Comparative Sample 6 (CS6),Sample 7 (S7), and Comparative Sample 8 (CS8), described in Table 8. S5is a low-flow benzophenone-BPA copolymer composition having a meltvolume flow rate (MVR) of 2.81 cm³/10 minutes at 300° C., 1.2 kg, 360seconds, and an abusive MVR of 2.89 cm³/10 minutes at 300° C., 1.2 kg,1080 seconds. CS6 is a low-flow BPA-polycarbonate composition having anMVR of 6.35 cm³/10 minutes at 300° C., 1.2 kg, 360 seconds, and anabusive MVR of 6.52 cm³/10 minutes at 300° C., 1.2 kg, 1080 seconds. S7is a high-flow benzophenone-BPA copolymer composition having a meltvolume flow rate (MVR) of 11.5 cm³/10 minutes at 300° C., 1.2 kg, 360seconds, and an abusive MVR of 11.7 cm³/10 minutes at 300° C., 1.2 kg,1080 seconds. CS8 is a high-flow BPA-polycarbonate composition having anMVR of 27.6 cm³/10 minutes at 300° C., 1.2 kg, 360 seconds, and anabusive MVR of 27.7 cm³/10 minutes at 300° C., 1.2 kg, 1080 seconds.

TABLE 8 Sample Ingredient Unit S5 CS6 S7 CS8 High-Flow Benzophenone- %100 BPA copolymer Low-Flow Benzophenone- % 100 BPA copolymer High-FlowBisphenol-A % 100 based polycarbonate resin Low-Flow Bisphenol-A % 100based polycarbonate resin Potassium Perfluorobutane % 0.08 0.08 0.080.08 Sulfonate Irgaphos Stabilizer % 0.06 0.06 0.06 0.06 Melt VolumeFlow Rate cc/10 2.81 6.35 11.5 27.6 min Abusive Melt Volume Flow cc/102.89 6.52 11.7 27.7 Rate min

Flammability testing was conducted using the standard UnderwritersLaboratory UL 94 test method (7 day conditioning). 5 bars and 3 plaqueswere tested. Specimens are to be preconditioned in an air-circulatingoven for 168 hours at 70±1° C. and then cooled in a desiccator for atleast 4 hours at room temperature, prior to testing. Once removed fromthe desiccator, specimens are tested within 30 minutes. The data for thebars was analyzed by calculation of the average flame out time, standarddeviation of the flame out time and the total number of drips.Statistical methods were used to convert the data to a probability thata specific formulation would achieve a first time pass or “p(FTP)” inthe standard UL 94 testing of 5 bars. Preferably p(FTP) values will be 1or very close to 1 for high confidence that a sample formulation wouldachieve a 5VA rating in UL 94 testing.

Table 9 presents the 5VA test results for the low-flow and high-flowbenzophenone-BPA copolymer compositions S5 and S7 as compared withlow-flow and high-flow BPA-polycarbonate compositions lackingbenzophenone endcap. The data of Table 9 demonstrates that theUV-treated high-flow and low-flow compositions incorporating4-hydroxybenzophenone endcap (e.g., S5 and S7) can meet 5VA materialrequirements at thicknesses of 2.5 mm or less, 2.0 mm or less, and 1.5mm or less, whereas corresponding controls with the high-flow andlow-flow BPA-polycarbonate (e.g., CS6 and CS8) do not show any variationin their respective flame resistance after UV-treatment. The failure ofUV-treated Sample 7 (S7) at 1.5 mm indicates that endcap mol % andpolymer molecular weight may be balanced to achieve 5VA performance.

TABLE 9 Sample Flame Resistance S5 CS6 S7 CS8 Before UV 5VA @ 3 mm F F FF 5VA @ 2.5 mm F F F F 5VA @ 2 mm F F F F 5VA @ 1.5 mm F F F F After UV5VA @ 2.5 mm P F P F 5VA @ 2 mm P F P F 5VA @ 1.5 mm P F F F P =specimens that passed 5VA testing; F = specimens that failed 5VA testing

The results of Tables 7 and 9 demonstrate that the cross-linkedpolycarbonates disclosed herein, whether neat or within a blendcomposition, impart flame resistance (V0 and 5VA) to articles comprisingthe cross-linked polycarbonates. In particular, the compositions can beused to provide 5VA compliant materials and articles.

The results also demonstrate that even benzophenone-BPA compositionsincorporating UV-absorbing polymers (e.g., p-cumylphenol capped ITR-PC)can undergo sufficient cross-linking to provide compositions thatexhibit V0 and 5VA performance according to UL 94.

The results further demonstrate that 5VA performance can, surprisingly,be achieved using 0.08 wt % or less of a non-brominated, non-chlorinatedflame retardant. This allows preparation of compositions comprising thecross-linked polycarbonates that have high transparency and low hazevalues. In particular, the cross-linked compositions can be used toprovide 5VA compliant materials at 2.5 mm or less, 2 mm or less, and 1.5mm or less, the materials having high transparencies and low hazevalues. In comparison, conventional polycarbonate cannot achieve 5VAperformance without incorporation of significant quantities of flameretardant, which may lower the transparency of the resultingpolycarbonate and effect overall physical properties.

(D) Mechanical and Physical Properties

Improved flame retardance as demonstrated above for the cross-linkedcompositions is generally not useful if the composition also hasexcessive loss of mechanical properties that are needed for end useapplications. As demonstrated below, the cross-linked compositionsretain impact and tensile properties subsequent to UV-treatment.

Table 10 provides mechanical and physical properties of the compositionsof Sample 5 (S5), Comparative Sample 6 (CS6), Sample 7 (S7), andComparative Sample 8 (CS8), the formulations for which are describedabove in Table 8. The properties provided in Table 10 relate to thesamples before UV-treatment. Table 10 shows that the compositions thatincorporate benzophenone endcapped-resin exhibit similar mechanicalproperties to the ones that incorporate conventional BPA-polycarbonateresin.

TABLE 10 Property (before UV- Sample treatment) Unit S5 CS6 S7 CS8Modulus of MPa 2354 2332 2388 2372 Elasticity Tensile Strength MPa 64 6670.6 68 at Break Flexural Modulus MPa 2310 2290 2360 2360 FlexuralModulus — 77.4 53.1 7.36 16.3 Flexural Modulus % 3.35 2.32 0.312 0.692NII Ductility % 100 100 100 100 NII Impact Strength J/m 920 911 845 685HDT ° C. 135.8 133.8 131.5 129.6 MVR cm³/10 2.81 6.35 11.5 27.6 minAbusive MVR cm³/10 2.89 6.52 11.7 27.7 min NII = Notched Izod Impact;HDT = Heat Distortion Temperature; MVR = Melt Volume Flow Rate

The dynamic oscillatory rheology curves of low-flow benzophenone-BPAcopolymer resin (S5) and low-flow bisphenol-A based polycarbonate resin(CS6) were run on an ARES strain controlled rheometer using a frequencysweep method to determine the viscosity or modulus of the material as afunction of frequency at a constant temperature (300° C.). Frequencysweep measurements were performed using 25 mm parallel-plate geometry ata 20% strain (linear regime) with a fixed gap of 1 mm. The frequency wasvaried from 0.1 to 500 rad/s.

The dynamic oscillatory rheology curve of low-flow bisphenol-A basedpolycarbonate resin is shown in FIG. 6; the dynamic oscillatory rheologycurve of cross-linkable low-flow benzophenone-BPA copolymer resin isshown in FIG. 7. The dynamic oscillatory rheology was determined onpellets of the resins as a function of passes through a UV Fusion FS300Swith a LC-6B Benchtop Conveyor using a D bulb. The time of irradiationwas ˜90 seconds, providing energy of irradiation of ˜3,000 mJ/cm². FIG.7 shows there is a dramatic increase in the elastic modulus for thebenzophenone capped material. For example, at 0.1 rad/s the elasticmodulus grows from 10 Pa to 10000 Pa (three orders of magnitude) from 0to 5 passes, whereas in the low flow BPA poly-carbonate materials (FIG.6) the elastic modulus is just 2 Pa irrespective of the UV passes. Thisdramatic increase in elastic modulus as a function UV exposure for thebenzophenone capped material material indicates the formation ofcrosslinking in the benzophenone end capped polycarbonate.

Table 11 shows multiaxial impact (MAI) data for the compositions bothprior to and after UV-exposure. As shown in Table 11, the improved flameresistance of the present compositions comprising cross-linkedpolycarbonate is achieved without significant loss of importantmechanical properties.

TABLE 11 Sample Test (3.2 mm disk) Unit S7 S7 S7 UV-dose mJ/cm² 0 10002000 MAI - Energy to max load J 75.4 62.4 62.9 MAI - Energy to failure J80.5 69.1 67.5 MAI - Energy, Total J 80.5 69.1 67.6 MAI - Max load kN7.14 6.653 6.209 MAI - Deflection at max load mm 21.3 19.6 19.9 MAI -Ductility % 100 100 100

Table 12 shows that tenisle properties of the cross-linked polycarbonatecompositions prepared by sun exposure are not effected by UV exposure.At T₀ (zero hours exposure) the compositions of Sample S5 had anelongation at break of 141.22% (50 mm/min elongation speed). At 168hours, the elongation break was 126.23%. By way of comparison, 100 gr PChad an elongation at break of 119.21% at T₀. Thus, the tensile strengthof the cross-linked compositions is retained after UV-exposure.

TABLE 12 Elongation at Break (%) Sun Exposure (h) Example S5 100 gr PC 0141.22% 119.21% 24 121.08% — 48 123.04% — 168 126.23% —

FIG. 8 shows that cross-linking is limited to the surface of a treatedarticle. Tensile bars prepared from S5 were elongated and thereafterexamined under field emission microscopy (FEM). FIG. 8 illustrates thatmicro cracks formed during tensile elongation were of approximately 20microns deep or less. The depth of cross-linking is estimated to around20 microns or less, 15 microns or less, 10 microns or less, or 5 micronsor less.

(E) Chemical Resistance

Compositions comprising cross-linked polycarbonates disclosed hereinwere evaluated for chemical resistance. Powders of4-hydroxybenzophenone-terminated polycarbonates (Examples 3-5),formulated with a phosphite stabilizer and a hindered phenol, were eachstabilized and subsequently pelletized to provide composition samplesS9-S11. The resulting pellets were molded in the form of 3.2 mmcolorchips. Table 13 presents the constituents, the glass transitiontemperature (Tg), and the melt volume flow rate (MVR) for each sample.

TABLE 13 Sample Ingredient Unit S9 S10 S11 Example 3 Benzophenone-BPA %100 copolymer - 1.7 mol-% - 28k Example 4 Benzophenone-BPA % 100copolymer - 2.5 mol-% - 27k Example 5 Benzophenone-BPA % 100 copolymer -0.5 mol-% - 28k Phosphite % 0.06 0.06 0.06 Stabilizer Hindered Phenol %0.05 0.05 0.05 Stabilizer MVR Melt Volume cc/10 5.3 4.8 8.1 Flow Ratemin Abusive Abusive Melt cc/10 5.4 5.6 8.6 MVR Volume Flow Rate min TgGlass Transition ° C. 151.7 151.7 152.1 Temperature

Colorchips of S9-S11 were plunged into a test fluid for a duration of 5minutes to assess chemical resistance to the fluid. Table 14 shows thechemical resistance of each composition S9-S11 to toluene, acetone, andWindex®. Table 14 shows that higher amounts of 4-hydroxybenzophenoneendcap (e.g., 2.5 mol % as in S10) led to improved chemical resistance,independently of the resin molecular weight. The non-UV treatedcolorchips, when treated with acetone or toluene, exhibitedcrystallization and shrinking on the colorchip surface.

TABLE 14 Sample Chemical Resistance S9 S10 S11 Before UV toluene − − −acetone − − − Windex ® +++ +++ +++ After UV toluene + ++ + acetone +++ + Windex ® +++ +++ +++ “−” = cracking/blistering observed; “+” =lowered gloss observed; “++” = solvent mark observed; “+++” = no visualchange observed

Table 15 shows that UV-irradiated samples S1 and S3, the formulationsfor which are described above in Table 6, are resistant to chemicaltreatment after exposure to UV radiation, as compared to the respectivecontrol samples CS2 and CS4. Surprisingly, even benzophenone-BPA blendsincluding UV-absorbing polymers (e.g., p-cumylphenol capped ITR-PC) suchas that of S1 underwent sufficient cross-linking to provide compositionsthat exhibit extreme chemical resistance (e.g., resistance to acetone).

TABLE 15 Sample S1 CS2 (blend) (blend) S3 CS4 Chemical (HBP-BPA/(HF-BPA/ (neat) (neat) Resistance ITR-PC) ITR-PC) (HBP-BPA) (HF-BPA)Before toluene − − − − UV acetone − − − − Windex ® +++ +++ +++ +++ Aftertoluene +++ − +++ − UV acetone ++ − ++ − Windex ® +++ +++ +++ +++ “−” =cracking/blistering observed; “+” = lowered gloss observed; “++” =solvent mark observed; “+++” = no visual change observed; HBP-BPA =Benzophenone-BPA copolymer - 2.5 mol-% - 26k; HF-BPA = High-FlowBisphenol-A based polycarbonate resin; HBP-BPA/ITR-PC = Benzophenone-BPAcopolymer - 2.5 mol-% - 26k/p-cumylphenol capped poly(20 wt %isophthalate-terephthalate-resorcinol ester)-co-(80 wt % bisphenol-Acarbonate) copolymer; HF-BPA/ITR-PC = High-Flow Bisphenol-A basedpolycarbonate resin/p-cumylphenol capped poly(20 wt %isophthalate-terephthalate-resorcinol ester)-co-(80 wt % bisphenol-Acarbonate) copolymer.

The cross-linked polycarbonate composition S5 was further evaluated forchemical resistance under strain conditions. In a strain jig, fourtensile bars were positioned. The tensile bars were molded at 550° F.barrel temperature, 180° F. mold temperature and 0.5 in/s injectionspeed. Two bars comprised the cross-linked polycarbonate composition S5,and two comprised the S5 composition prior to UV-treatment. Thecurvature of the jig induced a 1% stress level on the tensile bars. Aportion of the bars was exposed to acetone by dripping the solvent ontop of the tensile bars. As shown in Table 16, the tensile bars of thesamples without UV-treatment snapped upon exposure to acetone, whereasthe tensile bars comprised of the cross-linked polycarbonate did notsnap.

TABLE 16 Test Conditions Temper- Exposure Sample Strain ature TimeSolvent S5 Before 1% 23° C. Until solvent Acetone Bars snapped UVevaporates After 1% 23° C. Until solvent Acetone Bars did not snap UVevaporates

The chemical resistance results of Tables 14-16 demonstrate that thecross-linked polycarbonates disclosed herein, whether neat or within ablend composition, impart chemical resistance to articles comprising thecross-linked polycarbonate. The results also demonstrate that evenblends with UV-absorbing polymers can achieve sufficient cross-linkingto provide compositions that exhibit extreme chemical resistance.

(F) Haze

Compositions comprising cross-linked polycarbonates disclosed hereinwere evaluated for haze value. Percent haze (% Haze) was determined forthe compositions of samples S5 and S7, the formulations for which aredescribed above in Table 8. The percent haze for each sample was lessthan 2%, the haze value measured on 2.54 mm thick color chips using aColor-Eye 7000A Spectrometer.

It is understood that the foregoing detailed description andaccompanying examples are merely illustrative and are not to be taken aslimitations upon the scope of the invention, which is defined solely bythe appended claims and their equivalents.

Various changes and modifications to the disclosed embodiments will beapparent to those skilled in the art. Such changes and modifications,including without limitation those relating to the chemical structures,substituents, derivatives, intermediates, syntheses, compositions,formulations, or methods of use of the invention, may be made withoutdeparting from the spirit and scope thereof.

What is claimed is:
 1. A process for preparing an article, comprising:(a) providing a composition comprising (i) a non-cross-linkedpolycarbonate comprising about 0.5 mol % to about 5 mol % endcap groupsderived from a monohydroxybenzophenone, and (ii) a flame retardant; (b)molding the composition of step (a) into an article, or coating anarticle with the composition of step (a); and (c) exposing the moldedarticle or coated article of step (b) to UV-radiation by passing thearticle through a UV-chamber, UV-containing light source, or exposingthe article to the sun, to affect cross-linking of the non-cross-linkedpolycarbonate; wherein a plaque formed from the composition achieves aUL 94 5VA rating at a thickness of 3.0 mm (±10%) or less after UVexposure.
 2. The process of claim 1, wherein the non-cross-linkedpolycarbonate comprises about 1 mol % to about 3 mol % endcap groupsderived from a monohydroxybenzophenone.
 3. The process of claim 1,wherein the plaque achieves a UL94 5VA rating at a thickness of 2.0 mm(±10%).
 4. The process of claim 1, wherein the plaque achieves a UL945VA rating at a thickness of 1.5 mm (±10%).
 5. The process of claim 1,wherein the flame retardant is potassium perfluorobutane sulfonate(Rimar salt), potassium diphenyl sulfone-3-sulfonate (KSS), or acombination thereof.
 6. The process of claim 1, wherein the compositionfurther comprises a cyclic siloxane.
 7. The process of claim 1, whereinthe flame retardant is present in an amount of about 0.08 wt % or less,based on the total weight of the composition.
 8. The process of claim 1,wherein the plaque achieves a UL94 5VA rating in the absence of abrominated and/or chlorinated flame retardant.
 9. The process of claim1, wherein the plaque has a transparency of 70% or greater at athickness of 3.2 mm, measured according to ASTM-D1003-00.
 10. Theprocess of claim 1, wherein the plaque has a haze value of less than 10%at a thickness of 3.2 mm, measured according to ASTM D1003-00.
 11. Theprocess of claim 1, wherein when the exposed article is an ASTM part,the part has full ductility under multiaxial impact test conditions perASTM D3763 at −30° C. determined using a 4-inch (10 cm) diameter, 3.2millimeter (mm)-thick disk sample, ½-inch (12.7 mm) diameter dart, andan impact velocity of 3.3 meters per second (m/s).
 12. The process ofclaim 1, wherein when the exposed article is a ASTM Type 1 tensile bar,the bar has an elongation at break of at least 100% using the ASTM D 638Type I method at 50 mm/min after exposure to acetone under 1% strain at23° C.
 13. The process of claim 1, wherein when the exposed article isan ASTM part, the part has an elongation at break of 50% to about 200%according to ASTM D
 638. 14. The process of claim 1, wherein thenon-cross-linked polycarbonate has a molecular weight greater than17,000 Daltons and less than or equal to 80,000 Daltons, as measured bygel permeation chromatography using polycarbonate standards.
 15. Theprocess of claim 1, wherein the non-cross-linked polycarbonate has amelt volume flow rate ranging from about 5 to about 30 cc/10 min at 300°C./1.2 kg.
 16. The process of claim 1, wherein themonohydroxybenzophenone is 4-hydroxybenzophenone.
 17. The process ofclaim 1, wherein the cross-linked polycarbonate comprises repeatingunits derived from bisphenol-A.
 18. The process of claim 1, wherein thenon-cross-linked polycarbonate has repeating units having branchinggroups.
 19. The process of claim 1, wherein the non-cross-linkedpolycarbonate comprises a compound of formula (I),

wherein each repeating unit —O—Z—OC(═O)— is independently derived from acarbonate source and (i) a monomer having the structure HO-A₁-Y₁-A₂-OHwherein each of A₁ and A₂ comprise a monocyclic divalent arylene group,and Y₁ is a bridging group having one or more atoms; or (ii) a monomerhaving the structure

wherein each R^(h) is independently a halogen atom, a C₁-C₁₀hydrocarbyl, or a halogen substituted C₁-C₁₀ hydrocarbyl, and n is 0 to4; R¹ is halogen, C₁-C₆ alkyl, C₃-C₈ cycloalkyl, aryl, or arylalkyl; R²is halogen, C₁-C₆ alkyl, C₃-C₈ cycloalkyl, aryl, or arylalkyl; x is 0,1, 2, 3, or 4; y is 0, 1, 2, 3, 4, or 5; and n′ ranges from 29 to 65.20. The process of claim 19, wherein the non-cross-linked polycarbonatecomprises a compound of formula (II):

wherein n′ ranges from 29 to
 65. 21. The process of claim 1, wherein theplaque contains at least 5 wt % of an insoluble methylene chlorideinsoluble fraction in a 1 mm thick film.
 22. The process of claim 1,wherein the composition further comprises one or more additionalpolymers, and optionally one or more additives.
 23. The process of claim22, wherein the composition further comprises a p-cumyl phenol cappedpoly(isophthalate-terephthalate-resorcinol ester)-co-(bisphenol-Acarbonate) polymer or a polycarbonate polysiloxane copolymer wherein thepolysiloxane content is from 0.4 wt % to 25 wt %.
 24. The process ofclaim 23, wherein the polycarbonate polysiloxane copolymer is a siloxaneblock co-polycarbonate comprising from about 6 wt % siloxane (±10%) toabout 20 wt % siloxane (±10%).
 25. The process of claim 1, wherein theplaque formed from the composition, comprising potassium perfluorobutanesulfonate (Rimar salt) in an amount of about 0.05 wt % to about 0.085 wt%, based on the total weight of the composition, achieves a UL94 5VArating at a thickness of 3.0 mm (±10%) or less in the absence of abrominated and/or chlorinated flame retardant; and wherein the plaquehas a transparency of 70 to 90% at a thickness of 3.2 mm, measuredaccording to ASTM-D1003-00.
 26. The process of claim 25, wherein thepotassium perfluorobutane sulfonate (Rimar salt) is present in an amountof about 0.06 wt % to about 0.08 wt %.
 27. The process of claim 25,wherein the cross-linked polycarbonate does not contain any soft blocksegments from aliphatic polyesters, aliphatic polyethers, aliphaticpolythioeithers, aliphatic polyacetals, aliphatic polycarbonates, C—Clinked polymers, or polysiloxanes.
 28. The process of claim 25, whereinthe cross-linked polycarbonate does not contain any repeating unitsderived from a dihydroxybenzophenone, a trihydroxybenzophenone, or atetrahydroxybenzophenone.
 29. The process of claim 1, wherein thearticle is at least one of an automotive bumper, an automotive exteriorcomponent, an automobile mirror housing, an automobile wheel cover, anautomobile instrument panel or trim, an automobile glove box, anautomobile door hardware or other interior trim, an automobile exteriorlight, an automobile part within the engine compartment, an agriculturaltractor or device part, a construction equipment vehicle or device part,a marine or personal water craft part, an all terrain vehicle or allterrain vehicle part, plumbing equipment, a valve or pump, an airconditioning heating or cooling part, a furnace or heat pump part, acomputer part, a computer router, a desk top printer, a largeoffice/industrial printer, an electronics part, a projector part, anelectronic display part, a copier part, a scanner part, an electronicprinter toner cartridge, a hair drier, an iron, a coffee maker, atoaster, a washing machine or washing machine part, a microwave, anoven, a power tool, an electric component, an electric enclosure, alighting part, a dental instrument, a medical instrument, a medical ordental lighting part, an aircraft part, a train or rail part, a seatingcomponent, a sidewall, a ceiling part, cookware, a medical instrumenttray, an animal cage, fibers, a laser welded medical device, fiberoptics, a lense (auto and non-auto), a cell phone part, a greenhousecomponent, a sun room component, a fire helmet, a safety shield, safetyglasses, a gas pump part, a humidifier housing, a thermostat controlhousing, an air conditioner drain pan, an outdoor cabinet, a telecomenclosure or infrastructure, a Simple Network Detection System (SNIDS)device, a network interface device, a smoke detector, a component ordevice in a plenum space, a medical scanner, X-ray equipment, aconstruction or agricultural equipment, and a turbine blade.
 30. Theprocess of claim 29, wherein the article is at least one of a computerhousing, a computer housing or business machine housing or part, ahousing or part for monitors, a computer router, a copier, a desk topprinter, a large office/industrial printer, a handheld electronic devicehousing, a housing for a hand-held device, a component for a lightfixture, a humidifier housing, a thermostat control housing, an airconditioner drain pan, an outdoor cabinet, a telecom enclosure orinfrastructure, a Simple Network Intrusion Detection System (SNIDS)device, a network interface device, a smoke detector, a component ordevice in a plenum space, a component for a medical application or adevice, an electrical box or enclosure, and an electrical connector. 31.A process for preparing an article, comprising: (a) providing acomposition comprising (i) a non-cross-linked polycarbonate comprisingabout 0.5 mol % to about 5 mol % endcap groups derived from amonohydroxybenzophenone, and (ii) a flame retardant; (b) molding thecomposition of step (a) into an article, or coating an article with thecomposition of step (a); and (c) exposing the molded article or coatedarticle of step (b) to UV-radiation for 90 seconds, providing an energyof irradiation of 3,000 mJ/cm², to affect cross-linking of thenon-cross-linked polycarbonate; wherein a plaque formed from thecomposition achieves a UL 94 5VA rating at a thickness of 3.0 mm (±10%)or less after UV exposure.
 32. A process for preparing an article,comprising: (a) providing a composition comprising (i) anon-cross-linked polycarbonate comprising about 0.5 mol % to about 5 mol% endcap groups derived from a monohydroxybenzophenone, and (ii) a flameretardant; (b) molding the composition of step (a) into an article, orcoating an article with the composition of step (a), using extrusionprocesses, multilayer extrusion processes, and combinations thereof; and(c) exposing the molded article or coated article of step (b) toUV-radiation to affect cross-linking of the non-cross-linkedpolycarbonate; wherein a plaque formed from the composition achieves aUL 94 5VA rating at a thickness of 3.0 mm (±10%) or less after UVexposure.
 33. A process for preparing an article, comprising: (a)providing a composition comprising (i) a non-cross-linked polycarbonatecomprising about 0.5 mol % to about 5 mol % endcap groups derived from amonohydroxybenzophenone, and (ii) a flame retardant; (b) molding thecomposition of step (a) into an article, or coating an article with thecomposition of step (a); and (c) exposing the molded article or coatedarticle of step (b) to UV-radiation to affect cross-linking of thenon-cross-linked polycarbonate; wherein a plaque formed from thecomposition achieves a UL 94 5VA rating at a thickness of 3.0 mm (±10%)or less after UV exposure; and wherein the molded article and/or coatedarticle of step (b) includes a multilayer sheet or multilayer film,wherein the composition is present in at least one of the outer layers.